HK1180781B - Housing, electronic device, apparatus, method and flat object ejector assembly - Google Patents

Description

Shell, electronic equipment, device and method and flat object ejector assembly

Technical Field

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

Background

In recent years, portable computing devices (e.g., laptop computers, PDAs, media players, cellular telephones, etc.) have become smaller, lighter, and more powerful. One factor contributing to this reduction in size may be attributed to the ability of manufacturers to manufacture the various components of these devices in increasingly smaller sizes while increasing the capabilities and/or operating speeds of such components in most cases. This trend to be smaller, lighter, and more powerful presents a continuing design challenge to the design of certain elements of portable computing devices.

One design challenge associated with portable computing devices is the design of a housing for housing (house) various internal components. This design challenge typically stems from several conflicting design goals, including the desire to make the chassis lighter and thinner, and the desire to make the chassis stronger and more aesthetically pleasing. Lighter enclosures (which typically utilize thinner structures and fewer fasteners) tend to be more deformable, and therefore they have a greater tendency to bend and deform when used, while stronger and more rigid enclosures (which typically utilize stronger structures and include fasteners) tend to be thicker and carry more weight. Unfortunately, however, the increased weight associated with a more robust chassis can lead to user dissatisfaction, and the flexing of the chassis formed from lightweight materials can lead to damage to some of the internal components of the portable device (e.g., the printed circuit board).

Further, a chassis is a mechanical assembly having multiple components that are screwed, bolted, riveted, or otherwise fastened together at discrete points. These assembly techniques typically complicate the chassis design and present an aesthetic impediment due to the presence of undesirable cracks, seams, gaps or breaks in the mating surfaces and the placement of fasteners along the housing surfaces. For example, when utilizing upper and lower housings, a mating line is created around the entire housing. Also, the various elements and complex processes used to manufacture the portable devices can make assembly time consuming and require cumbersome processes, such as requiring highly trained assembly operators to work with specialized tools.

Another challenge relates to techniques for mounting structures within a portable computing device. Conventionally, the structure has been positioned over one of the housings (either the upper or lower housing) and attached to one of the housings with fasteners (e.g., screws, bolts, rivets, etc.). That is, the structure is layered over the shell in a sandwich-like manner and then fastened to the shell. This method suffers from the same disadvantage as described above, that assembly is a time consuming and cumbersome process.

From a visual standpoint, users often find the compact and elegant design of consumer electronic devices more aesthetically appealing. For example, thin and lightweight portable electronic device designs are often popular with consumers. To achieve this type of design, a portable electronic device may include a thin profile housing and a number of different components built in. For example, the display, the main logic board including the processor and memory, the battery, the audio circuitry, the speaker, and the external interface circuitry may be disposed within a thin profile housing.

One advantage of portable electronic devices is that they can be moved and used in a number of different environments. External communication and data connections are required when moving between environments. To meet this demand, a general approach is to implement wireless solutions on portable electronic devices. The wireless solution may include implementing a wireless protocol and providing one or more antennas on the device.

One design goal for wireless solutions is consistent wireless performance over a wide range of operating conditions. One challenge in achieving consistent wireless performance is that materials desired to meet aspects of the overall design that differ from wireless performance may negatively impact their wireless performance. For example, to achieve strength and rigidity goals, it may be desirable to use a radio opaque material for the housing or equipment components to block antenna reception. Another challenge to achieve consistent wireless performance is that in compact devices with limited packaging space, elements that can generate or can be induced to generate signals that are detrimental to wireless performance may be packaged in close proximity to the antenna.

The growth of mass-manufactured portable electronic devices has prompted innovations in the functional and aesthetic design practices of enclosures enclosing such devices. The manufactured device may include a housing that provides an ergonomic shape and an aesthetically pleasing visual appearance desired by a user of the device. The outer surface of the metal alloy housing of the portable electronic device may be shaped by computer numerically controlled mechanical equipment and may include a combination of flat and curved regions. To minimize the weight of the portable electronic device, the metal alloy housing may be formed to a minimum thickness while maintaining sufficient mechanical strength to prevent minor impact damage. Since the thickness of the metal alloy housing may be very thin, e.g., a fraction of a millimeter, the shaping of the outer housing may require precise and repeatable results to minimize surface variations on the exterior of the housing. Surface irregularities can cause the metal alloy housing to have an unacceptable appearance or compromised mechanical integrity. Further, high volume manufacturing may require forming the metal alloy shell in a minimum amount of time. Multiple independent tools for shaping different regions of the metal alloy shell may require additional manufacturing time than machining along a single continuous path with a single cutting tool. There is therefore a need for a method and apparatus for machining the three-dimensional top, edge and bottom surfaces of a metal alloy shell to provide a surface having consistent surface variations within the required tolerances to achieve the desired minimum thickness shell and preferred surface appearance upon completion.

The growth of mass-manufactured portable electronic devices has prompted innovations in the functional and aesthetic design practices of enclosures enclosing such devices. The manufactured device may include a housing that provides an ergonomic shape and an aesthetically pleasing visual appearance desired by a user of the device. The edge surface of the housing may be shaped in a geometry with a curved portion that seamlessly joins with the flat bottom surface without a substantially flat portion along the edge surface. An opening in an edge surface of the housing is capable of receiving a removable flat object, such as a memory card or a tray for holding a memory card. When the flat object is stored in the housing, the outer portion of the flat object may be formed to abut against the curved surface of the housing to provide a smooth and uninterrupted surface. Mechanical ejection of the flat object may be achieved by inserting an ejection tool into an opening in the housing adjacent the flat object. In order to align the flat object with the circuit board within the housing, the flat object may be oriented parallel to the circuit board, typically parallel to a flat top or bottom surface of the housing. Since the edge surface of the housing may not be perpendicular to the flat surface of the housing, the flat object may be ejected in a direction not perpendicular to the curved edge surface of the housing but parallel to one of the flat surfaces. To minimize the size of the opening in the curved edge surface of the housing that can receive the ejection tool adjacent to the flat object, the center of the opening can be oriented perpendicular to the curved edge surface of the housing. The insertion angle of the ejection tool may not be parallel to the orientation of the flat object in the housing. There is thus a need for a method and a device for ejecting a flat object through a housing surface in a direction that is not parallel to the direction in which an ejection tool is inserted through an opening perpendicular to the housing surface.

In view of the foregoing, there is a need for an increased density of components and related assembly techniques that reduce costs and improve factory quality. Further, there is a need for improvements in the manner in which hand-held devices are assembled, such as improvements that enable the structure to be quickly and easily mounted within a housing. It is also desirable to minimize the Z-stack height of the assembled elements in order to reduce the overall thickness of the portable computing device, thereby improving the overall aesthetics and feel of the product. In view of the foregoing, there is a need for a method and apparatus for improving wireless performance in a portable electronic device.

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 the like. In one embodiment, a portable computing device may include at least one-piece housing having a surface for receiving a bezel bead (trim bead) and a transparent cover such that the transparent cover is supported by the housing. The one-piece housing may include an integral bottom and side walls that cooperate to form an internal cavity. The outer surface of the housing may have a substantially flat bottom, connected to a curved wall. The internal cavity may include a substantially flat bottom for mounting the battery pack and other components (e.g., a PCB board). Various structures including ledges, alignment points, attachment points, openings, and support structures may be formed in the sidewalls and floor of the internal cavity. The ledge around the perimeter of the interior cavity may include a surface for receiving the bezel bead and the transparent cover into the housing. In one embodiment, corner brackets may be mounted around the perimeter of the cavity. The corner bracket may be configured to reduce impact-induced damage at the corner.

In one aspect, the one-piece housing may be machined from a single billet (billet) material (e.g., a rectangular aluminum block) using a Computer Numerical Control (CNC) machine tool and related techniques. In one embodiment, the one-piece housing may be formed by: 1) machining the blank to form an outer surface of the housing, the outer surface including a curved sidewall that transitions to a substantially flat bottom surface; 2) machining the blank to form an internal cavity, a portion of the internal cavity being substantially flat and parallel to the substantially flat bottom surface; 3) machining the blank to form an interior sidewall to form a ledge extending from the sidewall, the ledge comprising a surface approximately parallel to the planar bottom surface for receiving a bezel bead and a cover, and 4) machining the blank to form a support bracket for attaching a corner bracket to the housing.

In certain embodiments, the corner brackets may be attached to the support bracket with an adhesive conductive foam to increase the rigidity and thus the resistance of the housing to damage from a collision event. The conductive foam may ground the corner bracket to the rest of the housing to ensure good antenna performance. The corner bracket may include surfaces for receiving corner portions of the bezel bead and the cover. The corner bracket may be mounted such that the top of the surface on the corner bracket for receiving the bezel bead is aligned with the surface for receiving the bezel bead formed on the ledge of the single-piece shell adjacent the corner bracket. In one embodiment, the surfaces on the corner brackets for receiving the edge frame strips may be castellated to increase the strength of the housing in a manner similar to a castellated building.

In another embodiment, multiple openings may be machined in a single piece housing to provide access to the internal cavity from outside the outer housing. For example, a first opening in the single-piece housing may be formed to allow a SIM tray for supporting a SIM card to extend from the interior cavity through and over one of the side walls, and a second opening in the single-piece housing adjacent to the first opening may be formed to allow access to the ejector mechanism for extending the SIM tray from within the cavity. As another example, an opening may be formed in the housing bottom configured to receive a logo laminate including a logo insert bonded to a metal plate. In another embodiment, a plurality of openings may be formed in the curved exterior sidewall of the enclosure to allow sound from the speaker to escape the enclosure. The holes may be machined from the outside to the inside in a direction orthogonal to the local curvature of the sidewall.

In another embodiment, the housing may be designed such that some structural integrity is maintained during cover failure. In one example, an adhesive (e.g., an adhesive tape) can be applied to the bottom of the cover. In the event of a failure of the cover, the adhesive tape can secure the portions of the cover together and prevent the cover from breaking into pieces.

The portable computing device may take many forms, such as a laptop computer, a tablet computer, and the like. A one-piece housing including an integrated bottom and side walls that cooperate to form an internal cavity may be used as the chassis. Device elements (e.g., display, battery pack, main logic board, memory, audio device) may be enclosed in the internal cavity. The element may be sealed in the internal cavity using a cap. In one embodiment, the one-piece housing may be formed of a radio opaque material and the cover may be formed of a radio transparent material that is also optically transparent, such as transparent glass.

The antenna system may be disposed in an interior cavity of the housing below the cover. The antenna system may include an antenna for transmitting or receiving wireless signals. An adhesive layer and a compressible foam layer may be provided for attaching the antenna to the bottom of the cover glass. The compressible foam layer may be configured to exert an upward force on the antenna to provide a relatively constant spacing between the antenna and the bottom of the cover in order to minimize an air gap between the bottom of the cover and the antenna. This relatively constant spacing and minimal air gap may help to improve the performance of wireless solutions implemented with antennas.

In one embodiment, an antenna may be coupled to the compressible foam layer. In another embodiment, an antenna carrier may be disposed between the antenna and the compressible foam layer, wherein both the antenna and the compressible foam may be coupled to the antenna carrier. The housing may be provided with an RF antenna window. In one embodiment, the antenna carrier may be configured to fit within the RF antenna window.

In another embodiment, a proximity sensor may be coupled to the antenna carrier, such as by engaging the proximity sensor to a compressible foam layer. The proximity sensor may be used to detect objects in the vicinity of the antenna. When an object is detected proximate to the antenna, a power level associated with the antenna may be adjusted. A shield may be disposed between the proximity sensor and the antenna. The shield can be used to prevent electromagnetic interference generated by the proximity sensor from reaching the antenna.

Another aspect of the invention provides a system. The system may include a metal housing having a surface for receiving the cover glass, the speaker assembly, and the antenna system. The speaker assembly may have a) a speaker enclosure having a metal portion for enclosing at least one speaker driver; b) a connector for grounding the speaker driver to the metal portion of the speaker enclosure; c) a conductive material wrapped around the speaker enclosure to form a faraday cage around the at least one speaker driver, the conductive material being grounded to the metal portion and the metal enclosure. The antenna system may be mounted to the bottom of the cover glass and the speaker assembly. In addition, the antenna system can be grounded on the metal shell. In one embodiment, the antenna system may be located near one side of the metal housing. The thickness of the metal housing at the side near the antenna system may be thinned for the performance of the antenna system.

A portable computing device is disclosed. The portable computing device may take many forms, such as a laptop computer, a tablet computer, and the like. In one embodiment, a portable computing device may include a single piece housing having a front opening. In the described embodiment, the one-piece housing may in turn include an integral bottom and side walls that cooperate with the front opening to assist in forming the cavity, wherein the inner surface of the bottom wall is substantially flat and the side walls are curved. In addition to the one-piece housing, the portable computing device can include elements including at least one battery cell and a main logic board mounted directly to a middle portion of the bottom wall. Other components, including sensors, antennas, buttons, switches, and speaker modules, may be disposed around the peripheral edges of the battery cells and the main logic board. The portable computing device may also include a display assembly mounted to the housing and a transparent cover disposed within the front opening and attached to the housing. The bottom of the one-piece housing and the mounted display assembly may form a protective enclosure for the battery cell.

In another embodiment, a portable computing device is disclosed. The portable computing device may include a single piece housing having a front opening. In the described embodiment, the one-piece housing can include an integral bottom wall and side walls that cooperate with the front opening to assist in forming the cavity, wherein the bottom wall has a substantially flat interior surface. The components (e.g., the battery cell and the main logic board) may be mounted directly to the inner surface of the bottom wall of the housing. The battery cells and the main logic board may lie substantially in the same plane, and the battery cells may expand into the spaces between the battery cells during operation. The display assembly may be disposed within the front opening and mounted to the housing such that the housing and the display assembly together form a protective enclosure for the battery cell.

In another embodiment, a portable computing device is disclosed. The portable computing device may include a single piece housing having a front opening. The one-piece housing may include integral bottom and side walls that cooperate with the front opening to assist in forming the cavity. The bottom wall of the housing may have a substantially flat inner surface surrounded by a plurality of grooves in the peripheral edge portion. The element may be mounted directly to the substantially flat inner surface of the bottom wall and at least one further element may be mounted in a recess in the peripheral edge portion. A display system and a transparent cover may be disposed in the front opening and attached to the housing.

In one embodiment, an apparatus for shaping an outer surface of a metal alloy case of a portable electronic device is disclosed. The apparatus includes a cutting tool having at least three cutting surfaces for grinding a region of the metal alloy housing. The apparatus also includes a Computer Numerically Controlled (CNC) positioning assembly configured to rotate the cutting tool at a constant rotational speed and contact the rotating cutting tool along a predetermined continuous path at a constant translational speed to grind the metal alloy shell. The at least three cutting surfaces of the cutting tool include a first flat cutting surface, a curved convex cutting surface, and a second flat cutting surface. The first flat cutting surface is proximate to the neck of the cutting tool and shapes a flat edge region on top of the metal alloy shell. The curved convex cutting surface is adjacent to the first flat cutting surface and shapes the curved edge region of the metal alloy shell. The second flat cutting surface is located at the cutting tool bottom adjacent to the curved convex cutting surface and shapes the flat bottom region of the metal alloy housing. The predetermined continuous path includes a continuous helical path for shaping a flat edge region of the metal alloy shell and a continuous zig-zag path for shaping a flat bottom region of the metal alloy shell. The spacing between adjacent loops (circuits) of the continuous helical path varies based on the curvature of the cross-section of the metal alloy casing surface.

In one embodiment, an apparatus for shaping an exterior surface of a metal alloy case of a portable electronic device includes a bell shaped cutting tool and a Computer Numerical Control (CNC) positioning assembly. The bell shaped cutting tool includes a plurality of cutting surfaces for grinding different regions of the metal alloy shell. The CNC positioning assembly is configured to rotate the bell shaped cutting tool at a constant rotational speed and contact the rotating bell shaped cutting tool along a predetermined path to grind the metal alloy shell. The adjacent cutting surfaces of the cutting tool are used to shape adjacent areas on the outer surface of the metal alloy housing.

In one embodiment, a method for processing an edge surface and a bottom surface of a metal alloy case of a portable electronic device includes at least the following steps. The first step includes grinding an edge surface of the metal alloy shell by contacting a rotating cutting tool against the edge surface along a first predetermined continuous helical path. The second step includes adjusting, for each loop of the continuous helical path, a pitch of the vertical movement of the cutting tool based on a final curvature of the metal alloy shell perpendicular to the direction of the continuous helical path along the surface of the metal alloy shell. The third step includes grinding the bottom surface of the metal alloy shell by contacting a rotating cutting tool against the bottom surface in a second predetermined alternating (altering) direction linear path.

Disclosed is a flat object ejector assembly comprising the following: a force-receiving mechanism arranged to receive a force (F) along a first axis_input) (ii) a And the flat object ejector includes: a tray having a receiving area adapted to support a flat object; a tray contact area arranged to receive an ejection force (F)_eject) An ejection force that causes at least a portion of the tray to be exposed after an ejection event; and an arm mechanically attached to the fulcrum. The arm receives a force (F) from the force-bearing mechanism at an arm input position_arm) And a force (F) applied at the arm input position_arm) Producing a lever action to exploit the ejection force (F)_eject) The ejecting end of the arm is driven to the tray contact area to apply a force (F)_input) An ejection event is initiated that causes the tray and the supported flat object to move in a direction along a second axis different from the first axis so as to partially expose a portion of the tray.

A flat object ejector assembly disposed within the housing has a sharply curved surface including a first orthogonal vector, the flat object ejector assembly being configured to receive an ejection tool substantially parallel to the first orthogonal vector such that the flat object ejector assembly partially ejects the flat object from the sharply curved surface of the housing at an angle that is non-collinear with the first orthogonal vector, wherein the ejection tool causes the ejector mechanism to rotate about a single axis such that the flat object is partially ejected.

In one embodiment, an apparatus in a portable electronic device is disclosed. The device includes at least a first pivot element, a second pivot element, and a foam element. The first pivot element is arranged to receive the ejection tool through a first opening in a housing of the portable electronic device in a concave receiving area of the first pivot element. The first pivot member is arranged to rotate about a first axis of rotation such that the cylindrical portion of the first pivot member contacts the curved portion of the second pivot member, thereby displacing the second pivot member. The second pivot member is arranged to rotate about a second axis of rotation in response to contact with the first pivot member and to cause the plate-like portion of the second pivot member to contact the flat object enclosed in the housing. The plate-like portion of the second pivot member displaces the flat object outwardly through a second opening in the housing of the portable electronic device when rotated about a second axis of rotation. A foam element disposed adjacent the second pivot element in the housing is arranged to rotate the second pivot element back to the neutral position.

In one embodiment, an apparatus in a mobile device is disclosed for ejecting a flat object initially contained therein. The device is arranged to receive an ejection tool along a first axis and eject the flat object along a second axis. The first and second axes are non-parallel to each other. In one embodiment, the device comprises a first pivot element arranged to receive the ejection tool and to rotate about a first axis of rotation to contact and displace a second pivot element. The second pivot member is arranged to rotate about a second axis of rotation in response to contact with the first pivot member. The second pivot member comprises a plate-like member which contacts the flat object and at least partially ejects the flat object from the mobile device. In one embodiment, the device includes a foam element disposed adjacent to the second pivot element. The foam element is compressed under rotation of the second pivot element when ejecting the flat object and decompresses (decompresses) when the ejection tool is removed, returning the second pivot element to the neutral position.

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 top perspective view of a portable computing device in accordance with the described embodiments.

Fig. 2 shows a perspective view of the exterior of a housing according to the described embodiment.

Fig. 3A shows a simplified top view of the interior of a housing according to the described embodiments.

Fig. 3B shows a perspective view of the interior of the housing according to the described embodiment.

FIG. 4A illustrates a perspective view of a corner of a housing according to the described embodiments.

Fig. 4B shows a stacked structure for attaching a corner bracket to a housing according to the described embodiments.

FIG. 5A shows a perspective view of one side of a housing including a lower portion of a ledge according to the described embodiment.

Fig. 5B shows a perspective view of a device attachment component incorporating a leaf spring as a locking mechanism according to the described embodiment.

Fig. 6 illustrates a perspective view of one side of a housing including a notch for an RF antenna window according to described embodiments.

Fig. 7A and 7B illustrate side views showing a mechanism for coupling a cover with a housing according to the described embodiments.

Fig. 8 shows a side view of a logo laminated structure according to the described embodiments.

FIG. 9 illustrates a method of forming a housing for a portable device according to the described embodiments.

FIG. 10 is a block diagram of an arrangement of functional modules utilized by a portable electronic device in accordance with the described embodiments.

FIG. 11 is a block diagram of an electronic device suitable for use with the described embodiments.

Fig. 12 shows a perspective view of an antenna window mounted to a housing according to the described embodiments.

Fig. 13A-13C show side views of an antenna stack-up structure according to a preferred embodiment.

Fig. 14 shows a side view of a laminated structure for joining a cover to a housing.

Fig. 15A and 15B show perspective views of an antenna stack-up structure located near an outer edge of a housing according to the described embodiments.

Fig. 16 is a perspective view of a speaker assembly according to the described embodiments.

FIG. 17 shows a side view of a display stack-up structure according to the described embodiments.

Fig. 18A and 18B illustrate a method of producing an antenna stack structure for a portable device according to the described embodiments.

FIG. 19 illustrates a top view of a portable computing device in accordance with the described embodiments.

FIG. 20 illustrates a top perspective view of a portable computing device in accordance with the described embodiments.

FIG. 21 illustrates a bottom perspective view of a portable computing device in accordance with the described embodiments.

FIG. 22 is a perspective view of an interior view of a housing of a portable computing device in accordance with the described embodiments.

FIG. 23 illustrates a top internal view of a portable computing device showing a particular arrangement of various internal elements, according to the described embodiments.

Fig. 24 shows an embodiment.

Fig. 25 shows a cross section along line AA of fig. 24.

Fig. 26 shows a cross section along the line BB of fig. 27.

Fig. 27 shows another embodiment.

FIG. 28 illustrates an exploded perspective view of the major elements of a portable computing device in accordance with the described embodiments.

Fig. 29 shows a more detailed view of a speaker module according to the described embodiments.

FIG. 30 illustrates a cross-sectional perspective view of a button assembly mounted through a cover glass of a portable computing device, in accordance with the described embodiments.

Figure 31 shows a top view of a portion of the button assembly of figure 30.

FIG. 32 is a side view of a portion of a display with alignment pins for a camera module.

Fig. 33 is a top plan view of the camera module.

Fig. 34 is a side view of a portion of a camera module and a flexible connector coupled thereto.

FIG. 35 shows a flow chart detailing a process according to the described embodiment.

Fig. 36 shows a simplified cross-sectional side view of a housing for a portable electronic device including a shaped geometric edge.

Fig. 37 shows a simplified cross section of a cutting tool for shaping the outer surface of the housing of fig. 36.

Fig. 38A-38D illustrate the positioning of different portions of the cutting tool for shaping different regions of the outer surface of the housing of fig. 36.

Fig. 39 shows the vertical path of the center of the cutting tool for a continuous loop of the helical path when shaping the outer surface of the housing of fig. 36.

Fig. 40 shows the variable pitch for a continuous loop of the helical path when shaping the outer surface of the casing of fig. 36.

Fig. 41 shows a top view of a portion of the continuous loop of the spiral path of fig. 40.

Fig. 42 shows a portion of a helical path for one region and a portion of a saw-tooth path for a second region of the outer surface of the housing of fig. 36.

FIG. 43 illustrates a representative method for shaping the outer surface of the housing of FIG. 36.

Fig. 44A shows a top view of a mobile device including a removable sliding tray.

Fig. 44B illustrates a front view of the mobile device of fig. 44A.

Fig. 44C shows a perspective view of the mobile device of fig. 44A.

FIG. 45A shows a top view of another mobile device that includes a removable sliding tray.

Fig. 45B shows a front view of the mobile device of fig. 44A.

Fig. 45C shows a perspective view of the mobile device of fig. 44A.

Fig. 45D shows a perspective view of a variation of the mobile device of fig. 44A.

Fig. 46 illustrates a partial perspective view of one embodiment of a flat object ejector assembly in accordance with the described embodiments.

FIG. 47 shows a full perspective view of the embodiment of FIG. 46 from another angle.

Fig. 48A, 48B and 48C show exploded views of the embodiment of fig. 46 showing different cross-sectional views of the embodiment.

Fig. 49 shows a perspective view of a second embodiment of a flat object ejector assembly according to the described embodiments.

Fig. 50 shows a perspective view of the embodiment of fig. 49 from another angle.

Fig. 51A, 51B and 51C show exploded views of the embodiment of fig. 50 showing different cross-sectional views of the embodiment.

Fig. 52 shows a perspective view of a third embodiment of a flat object ejector assembly according to the described embodiments.

Fig. 53 shows a perspective view of the embodiment of fig. 52 from another angle.

Fig. 54A, 54B and 54C show exploded views of the embodiment of fig. 49 showing different cross-sectional views of the embodiment.

Fig. 55 shows a flow chart detailing a manufacturing process for mounting a flat object ejector in a mobile device.

FIG. 56 shows a flowchart detailing an ejection process according to the described embodiment.

FIG. 57 shows a simplified top view of a representative means of ejecting a sliding tray from a mobile device.

Fig. 58 shows a perspective view of the device of fig. 57.

Fig. 59 shows a second perspective view of the device of fig. 57.

Fig. 60 shows a bottom view of the device of fig. 57.

Fig. 61 shows a detailed front exploded perspective view of a selection element of the device of fig. 57.

Fig. 62 shows a detailed rear exploded perspective view of a selection element of the device of fig. 57.

Fig. 63 shows front and rear views of the selection element of fig. 62 and 63 assembled together.

Fig. 64 shows left and right side views of the selection elements of fig. 61 and 62 assembled together.

Fig. 65 shows a perspective view of the selected elements of fig. 61 and 62 assembled together in a neutral "home" position.

Fig. 66 shows a perspective view of the selection elements of fig. 61 and 62 assembled together in an "eject" position.

Detailed Description

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the concepts upon which the described embodiments are based. 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, steps of well-known processes have not been described in detail in order to avoid unnecessarily obscuring the underlying concepts.

An aesthetically pleasing portable computing device that is easily carried with one hand and operated with the other hand is discussed herein. The portable computing device may be formed from a one-piece housing and an aesthetically pleasing protective top layer that may be formed from any of a number of robust and 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 high-polish cover glass without loss of generality. Furthermore, because (unlike conventional portable computing devices) the cover glass can be mounted to a single piece housing without the use of a bezel (bezel), the consistency of the appearance of the portable computing device can be enhanced. The simplicity of this design can produce many advantages for portable computing devices in addition to those associated with aesthetic look and feel. For example, assembly of a portable computing device may require fewer components and less time and effort, and a seamless, single-piece housing may provide superior protection of internal components from environmental contamination. Moreover, the ability of a portable computing device to successfully withstand applied loads (e.g., due to daily use) and to withstand less frequent but potentially more damaging events (e.g., being dropped) may be substantially enhanced over conventional portable computing devices.

In the described embodiments, the one-piece housing may be formed of plastic or metal. Where the one-piece housing is formed of metal, the metal (e.g., aluminum) may take the form of a single sheet of material. The single sheet of metal may be formed into a shape suitable for receiving various internal components and providing various openings into which switches, connectors, displays, etc. may be received. The one-piece housing may be forged, cast or otherwise processed into a desired shape. In one embodiment, the billet material (e.g., the material of a rectangular billet) may be machined to form a single piece housing.

One disadvantage of the choice of metal for use as the housing material is that metal is generally opaque to radio signals. Therefore, the choice of a metal material as the housing affects the placement of the antenna, i.e. the antenna needs to be placed in a position where the radio signals of the housing are not blocked by the surrounding radio-opaque material. One advantage of choosing metal as the housing is that the metal can provide a good electrical ground for any internal components that require a good ground plane. For example, built-in RF antenna performance may be substantially improved when a good ground plane is provided. Also, a good ground plane may be used to help mitigate deleterious effects due to, for example, electromagnetic interference (EMI) and/or electrostatic discharge (ESD). However, if the RF antenna is present inside the housing, a portion of the housing (if metal) may be dedicated to the radio transparent portion.

The shape of the housing may be asymmetric in that the upper portion of the housing may be formed to have a shape that is completely different from the shape exhibited by the lower portion of the housing. For example, the upper portion of the housing may have a surface that meets the unique angle forming a well-defined edge, while the lower portion may be formed to have a substantially flat bottom surface. The transition region between the upper portion having the distinct edge and the substantially flat lower portion may take the form of an edge having a rounded shape that provides both a natural variation from the upper portion of the housing (i.e., the region of the distinct edge) and a smoother surface presented by the lower portion of the housing. It should be noted that in addition to providing a more aesthetically pleasing transition, the rounded edges in the transition area may provide a more comfortable feel when the user holds it in his hand, whether in use or simply on his hand. One advantage of using metal as the housing is that the metal can provide a good electrical ground for any internal components that require a good ground plane. For example, built-in RF antenna performance may be substantially improved when a good ground plane is provided. Also, a good ground plane may be used to help mitigate deleterious effects due to, for example, electromagnetic interference (EMI) and/or electrostatic discharge (ESD). However, if the RF antenna is present inside the housing, at least a portion of the housing (if metal) may be dedicated to the radio transparent portion.

It should be noted that in the discussion that follows, the term "CNC" is used throughout. The abbreviation "CNC" stands for computer numerical control and refers in particular to a computer controller that reads computer instructions and drives a machine tool (power machine equipment, typically used to manufacture components by selective removal of material). It should be noted, however, that any suitable machining operation may be used to implement the described embodiments, and is not strictly limited to those CNC-related implementations.

These and other embodiments are discussed below with reference to fig. 1-66. However, those skilled in the art will readily appreciate that the detailed description given herein in connection with these figures is for explanatory purposes only and should not be construed as limiting. Implementing a wireless solution that provides consistent wireless performance over a wide range of operating conditions may include considering the relative radio transparency or opacity of each element of the portable device, the placement of the elements relative to each other, and the ability of each element to generate signals that may interfere with wireless reception. Thus, first, before describing particular features of the wireless solution, features of the portable computing device (including features affecting the wireless solution) are generally described with reference to FIGS. 1A-3C.

FIG. 1A illustrates a particular embodiment of a portable computing device 100. More particularly, FIG. 1A shows a complete 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 the like. For example, the portable computing device 100 may generally correspond to a device that may be implemented as a music player, a game player, a video player, a Personal Digital Assistant (PDA), a tablet computer, and/or the like. In a handheld aspect, the portable computing device 100 can be held in one hand by a user while being operated by the user's other hand (i.e., without the need for a reference surface such as a desktop). For example, a user may hold the portable computing device 100 in one hand while operating the portable computing device 100 with the other hand by, for example, operating a volume switch, a lock switch, or by providing input to a touch-sensitive surface (such as a display or a tablet). The device may also be operated while it is resting on a surface, such as a table.

The portable computing device 100 may include a single piece housing 102 that may be formed from any number of materials (e.g., plastic or metal) that may be forged, cast, machined, or otherwise processed into 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 a form having a radio (or RF) transparent material, such as ceramic or plastic. Examples of housings including radio transparent portions are described in more detail with reference to fig. 2, 3 and 6.

In either case, the housing 102 may be configured to at least partially enclose any suitable number of internal elements associated with the portable computing device 100. For example, the housing 102 may enclose and support various internal 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, which may include at least a microprocessor, 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 accommodate a system or display assembly 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 that provide the user with the ability to provide tactile input to the portable computing device 100 through the use of touch input. The display system may be formed and mounted separately from the cover 106. Cover 106 may be formed of polycarbonate or other suitable plastic or highly polished glass. By using a highly polished glass, the cover 106 may take the form of a cover glass that substantially fills the opening 104. Bezel bead 108 may be used to form a gasket (gasket) between cover glass 106 and housing 102. The bezel trim 108 may be formed from a resilient material such as thermoplastic polyurethane or TPU family plastic. In this manner, the bezel strip 108 can provide protection against environmental contaminants from entering the interior of the portable computing device 100.

Although not shown, a display panel under cover glass 106 may be used to display an image using any suitable display technology, such as LCD, LED, OLED, or electronic ink (e-ink), among others. In one embodiment, the display assembly and cover glass may be provided as an integrated unit for mounting into the housing. In another embodiment, the display assembly and cover glass 106 may be mounted separately.

The display assembly may be disposed and secured in the cavity using a variety of mechanisms. In one embodiment, the display assembly and housing 102 may include alignment points for receiving a fixture. The fixture can be used to precisely align the display assembly with the housing. In one embodiment, after the display assembly is aligned with the housing, it may be secured to the housing 102 with fasteners.

The portable computing device 100 may include a number of mechanical controls for controlling or 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 audio output by the portable computing device 100. It should be noted that each of the input mechanisms described above are typically disposed through an opening in the housing 102 to enable coupling with internal components. In some embodiments, the portable computing device 100 may include an image capture module 98 configured to provide still or video images. The layout may vary widely and may include one or more locations (including, for example, the front and 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 a mechanism for wireless communication, either as a transceiver-type device or merely a receiver (e.g., a radio), and the portable computing device 100 may include an antenna that may be disposed inside a radio-transparent portion of the housing 102. In other embodiments, a portion of the housing 102 may be replaced with a radio transparent material in the form of an antenna window, which will be described in more detail below. In some embodiments, the antenna may be below cover glass 106. 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, etc. Any number of antennas may be used, which may use a single window or multiple windows depending on system requirements.

The portable computing device may be used on a wireless data network, such as a cellular data network. Access to a cellular data network may require the use of a Subscriber Identity Module (SIM) or SIM card. In one embodiment, the device 100 may include an opening 110b that allows insertion or removal of a SIM card. In particular embodiments, the SIM card may be placed on a SIM card tray, which may extend from one side of housing 102. The housing may include an opening 110a that allows an ejector for the SIM card tray to be actuated to extend the SIM card tray from the housing. Openings 110a and 110B for the SIM card tray are shown in fig. 3B.

FIG. 1B illustrates a top perspective 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 for outputting audible sound. Sound generated by one or more internal speakers may pass through the housing 102 via the speaker grille 120. A portion of the speaker grille may be positioned on a downward facing side of the housing such that a portion of the sound is angled downward. When the device is placed on a surface, a portion of the downwardly emitted sound may be reflected off the surface on which the device is placed. Speaker grille 120 may be formed as a series of small holes punched through the housing sidewall. As described in more detail below, the sidewalls may be curved.

In one embodiment, the drill used to punch or drill the speaker hole may be oriented such that the hole is machined approximately normal to the surface curvature at each location. In some instances, more than one hole may be drilled at a time. For example, 5 holes are drilled in a row along a line of constant curvature so that all holes are drilled approximately normal to the surface. In one embodiment, the cover layers may be placed on the front and back of the housing when the hole is being machined. For example, a stainless sheet material may be placed over the outer surface of the housing and a plastic backing plate may be placed over the interior of the housing. The outer and inner covers prevent damage to the surrounding housing caused by material debris generated during processing. Creating holes in this manner allows for a smooth surface to be made without noticing the presence of holes when touched.

After the speaker grill holes are formed, a protective layer may be applied to the interior surface of the housing, covering the speaker grill holes. The protective layer may be designed to prevent the ingress of environmental contaminants, such as water that may enter the interior of the cavity through the speaker grill opening. In one embodiment, the protective layer may be formed from a hydrophobic fabric mesh that is permeable to sound to allow sound to pass through the speaker grille 120 while reducing the risk of environmental intrusion.

Returning to fig. 1B, the portable computing device 100 may also include one or more connectors for transferring data and/or power from the portable computing device 100 or to the portable computing device 100. For example, the portable computing device 100 may include multiple data ports, one configured for each of portrait and landscape modes. However, the presently described embodiment includes a single data port 122 that may be formed by a connector assembly 124, the connector assembly 124 being received within an opening formed along a first side of the housing 102. In this manner, when the portable computing device 100 is mounted to the dock, the portable computing device 100 can communicate with external devices using the data port 122. 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 then 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 be used as both a data and power port, thus eliminating the need for separate power connectors. The connector assembly 124 may vary widely. In one embodiment, the connector assembly 124 may take the form of a peripheral bus connector. In one embodiment, a connector assembly having 30 pins may be used. These connector types include both power and data functionality, allowing both 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 media portable computing device 100 may be powered by a host device that can be used to operate the portable computing device 100 and/or to charge a battery included therein while operating.

Fig. 2 shows a perspective view of the exterior of the housing 102 prior to assembly. The outer portion may serve as the bottom of the device when assembled. Fig. 3 depicts the interior of the housing and its associated components, which enclose the device elements (e.g., display assembly and main logic board). In one embodiment, the housing may be formed via machining of a single blank of material (e.g., a single aluminum blank formed into a rectangular shape). In fig. 2, a portion of the blank may be machined to form the overall exterior shape of the exterior of the housing. In other embodiments, the blank may be cast into a shape that more closely approximates the final shape of the housing before starting machining to form the final housing shape.

The housing 102 includes a substantially flat portion 144 surrounded by a curved sidewall 146. In one embodiment, the housing 102 may have a maximum thickness of less than 1 centimeter. In a particular embodiment, the maximum thickness is about 8 millimeters. In fig. 2, this geometry is provided for exemplary purposes only. In various embodiments, the curvature of the sidewalls (e.g., 146) and the area of the flat portion 144 may vary. In one embodiment, rather than the flat portion being connected to the curved sidewall, the sidewall and the flat portion may be combined into a shape having a continuous profile, such as conforming to a continuous spline curve. In other embodiments, the sidewall may be substantially flat and connected to the substantially flat portion via a specified radius of curvature without utilizing a curved sidewall.

Openings may be formed in the flat portion 144 and the side wall 146. The opening may be used for various purposes, including functional and decorative considerations. In one example, the opening may be used for a switch. As shown in fig. 2, the openings of the plurality of switches are formed in the side wall. For example, opening 136 is for a power control switch, opening 140 is for a slide switch and opening 142 is for a volume switch. In one embodiment, a slide switch may be used to provide mute control. In other embodiments, the slide switch may be used to control other device characteristics. The size of the opening may depend on the switch size. For example, the opening 142 may be used for a volume rocker switch, which may be larger than a power control switch or a mute control. In one embodiment, the opening may be formed using a drill bit oriented approximately normal to the surface of the housing 102. Therefore, its direction during machining may vary depending on where the sidewall is cut.

In another example, an opening for an external connector may be formed in the housing. For example, an opening 134 is provided in the sidewall for an audio port, such as for a headphone connector. In yet another example (see fig. 1B and 3B), an opening for an external data and power connector, such as a 30-pin connector, may be provided. In one embodiment, the opening may be cut in a direction approximately parallel to the flat portion of the housing, which may not be orthogonal to the curvature of the outer surface. Closer to the substantially flat portion of the housing 144, an opening 138 for the image capture device on the back is provided. Near the center of the substantially flat portion, an opening 130 is provided for the logo insert. The logo insert may be formed of a different material and color than the rest of the housing. Further details of the emblem insert are described with reference to fig. 8, which includes an emblem laminate structure for attaching an emblem to a housing.

The housing 102 may be formed of a radio opaque material (e.g., metal). In particular embodiments, the housing may include a notched portion for placing an RF antenna window to support one or more antennas. The housing may include a notch for receiving the RF antenna window 132. The RF antenna window may be formed of a radio transparent material (e.g., plastic) to enhance the reception of wireless data by the device. In fig. 2, the RF antenna window is shown in a mounted position extending across the side wall and ending near the substantially flat portion 144 of the housing. The RF antenna window 132 may be shaped to match the surface curvature profile of the adjacent sidewall. A view of the RF antenna window 132 and surrounding support structures on the housing as viewed across the interior of the housing is shown and described in more detail with reference to fig. 6.

In particular embodiments, a device may be configured to access a data network via one or more wireless protocols. For example, using a protocol (e.g., Wi-Fi), a device may be configured to access the internet via a wireless access point. As another example, using a wireless protocol (e.g., GSM or CDMA), a device may be configured to access a cellular data network via a local cellular telephone tower. Devices implementing two wireless protocols (e.g., Wi-Fi and GSM or Wi-Fi and CDMA) may use different antenna systems, one for Wi-Fi and one for GSM or CDM.

Typically, elements (e.g., RF antenna window 132) may be used to implement a cellular data network connection using GSM or CDM. To implement a wireless protocol (e.g., Wi-Fi), the RF antenna window 132 may not be necessary. Thus, in some embodiments, the housing may be formed without an opening for the RF antenna window 132. In these embodiments, the housing 102 may extend above the surface on which the RF antenna window 132 is located to conform to the circumferential curvature of the sidewall. Thus, the area in which the RF antenna window 132 is located may be formed of the same material as the rest of the housing 102 and processed in a similar manner to the other side walls of the housing.

Fig. 3A illustrates a top view of a simplified housing 102 showing a cavity with a front opening for one embodiment. A more detailed perspective view of the housing is described with reference to fig. 3B. In fig. 3A, the housing 102 may include substantially flat bottoms 148a and 148 b. The flat bottoms 148a and 148b may be at different heights or the same height. In one embodiment, the flat bottoms 148 and 148b may be substantially parallel to the flat outer bottom 144 of the housing described above with reference to fig. 2. The flat bottoms 148a and 148b may transition into sidewalls that extend above the cavity bottom.

The sidewalls may be cut from the lower portion to form ledges (e.g., ledges 156a, 156b, 156c, and 156d) that extend from the sidewalls to the center of the cavity. In one embodiment, the ledge may comprise portions at different heights. The width of the ledge may vary across each side edge as well as between the side edges. For example, the ledge 156a may be narrower in width than the ledge 156 d. The ledge need not be continuous across one side. In some embodiments, a portion of each ledge may be removed. Furthermore, the ledge width need not be constant across one side. In some embodiments, the ledge width may vary across one side edge.

Brackets (e.g., 150a, 150b, 150c, and 150d) may be located at each corner of the housing. The bracket may be formed of metal (e.g., stainless steel). The bracket may be configured to increase the structural rigidity of the housing. The corner bracket may limit the extent of impact damage, such as damage to the cover glass, in the event of a collision, such as at a corner of the housing. The shape of the bracket may vary between the corners. Furthermore, for illustrative purposes, a simplified shape of the bracket is shown, and different shaped brackets may be used. As discussed in more detail below, the bracket may be bonded to the housing with an adhesive. In one embodiment, the bracket may include surfaces for receiving corner portions of the bezel bead and the cover.

In one embodiment, elements (e.g., batteries) may be disposed in the regions 148a and 148 b. For example, in one embodiment, a plurality of battery packs may be joined to the housing in region 148a using PSA tape. In one embodiment, three battery packs may be adhered to the flat region 148a using an adhesive, which may take the form of an adhesive tape (e.g., PSA). The use of the adhesive tape can slightly raise the battery and provide a space for the battery pack to expand during operation. As another example, in the area 148b, a plurality of PCBs may be disposed. The number and type of PCBs may vary between embodiments depending on the functionality of the device. Some examples of PCBs that may be secured to the housing in this area include, but are not limited to, a main logic board, a battery management unit, and/or an RF circuit board. The RF circuit board may also include GPS circuitry. The attachment points may be machined as bumps (boss) into the bottom of the housing to secure the device components, such as the PCB. These are described in more detail with reference to fig. 3B.

Fig. 3B shows a perspective view of the interior of the housing 102. The device elements (e.g., display, processor board, memory, audio device) may be secured within a cavity formed by the housing. The housing 102 may include a substantially flat portion in its center that surrounds the opening 136 for the logo insert. As described in more detail with reference to fig. 8, the opening 136 may include a recessed ledge upon which a plate (e.g., a metal plate conforming to the shape of the recessed ledge) can be engaged to the housing to seal the opening 136.

A plurality of structures (e.g., protrusions 172a and 172b or protrusions 174 and 176) may be formed on the bottom of the housing. In one embodiment, the protrusion may be used with a fastener to secure one or more PCBs to the housing. For example, the bumps may be used to attach a main logic board, a battery management unit board, and a radio board. The number and type of plates may vary between embodiments. For example, certain embodiments do not include a radio board. Thus, the number and type of projections may vary between embodiments. The projections may include structures having holes that allow insertion of fasteners, such as metal or plastic screws. The structure may be formed by removing material during CNC-based machining. Attachment points, such as bumps, for other components, such as a display assembly or Wi-Fi antenna, may also be formed.

The housing 102 may include a number of components adjacent to the housing sidewalls and disposed near the housing perimeter. One example of a component is an opening in a sidewall. For example, the openings for audio port 134, power switch 136, mute button 140, and volume switch 142 described above with reference to FIG. 2, and the openings for data ports described above with reference to FIG. 1B are also visible in FIG. 3. The openings for the mute button 140, volume switch 142 and data port 122 are shown from the inside of the housing 102. As can be seen in fig. 3B, the structure in the vicinity of the opening on the inner side is different from the structure in the vicinity of the opening as viewed from the outer side. In particular, the outer surface of the housing near the opening is relatively smooth, without sharp edges, while the internal structure near the opening may include steps, ledges, walls, and other features. As discussed above, the exterior and interior of the housing may be asymmetric in this regard.

In fig. 3B, other openings include speaker hole notches 170 as viewed from the inside and openings for the SIM tray ejector mechanism 110a and SIM tray 110B as viewed from outside the housing 102. The openings for the SIM tray ejector mechanism 110a and the SIM tray 110b may be located on curved sidewalls of the housing 102. In one embodiment, the SIM tray 110a and the SIM tray opening 110b may be configured to allow the SIM tray to pop out in a plane that is substantially parallel to the flat portion of the bottom of the housing. However, the opening for the SIM tray ejector mechanism and the SIM tray ejector mechanism may be configured such that the opening 110a is bored approximately orthogonal to the surface according to the curvature of the side wall where it is located. The ejector mechanism may be configured to receive a tool (e.g., a cylindrical pin inserted through opening 110a normal to the surface) to eject the SIM tray. Thus, when the cylindrical pin is inserted into the opening 110a and the SIM tray is extended from the opening 110b, the SIM tray and the pin may form an angle with each other.

In certain embodiments, the ledge need not extend around the entire perimeter of the housing or completely across one side, as described with reference to FIG. 3A. For example, the housing does not include a ledge near where the RF antenna window 132 is located. In other embodiments that do not include an RF antenna window, the ledge may extend into the area occupied by the RF antenna window. In some locations, it may be difficult to achieve mounting of the components due to the presence of the ledge. At each location, the material may be removed so that ledges at the location are minimal or no ledges are formed. For example, near the openings 140 and 142 for the mute button and volume switch, respectively, the ledge may be removed and a cavity may be formed for receiving the mute button and volume switch assembly. The removed material near these openings may allow the mechanism for the mute button and volume switch to be inserted down into the housing such that a portion of the mechanism is accessible from outside the housing via the openings. In one embodiment, the housing of the switch assembly mounted in this manner may be shaped to provide a horizontal plane that aligns with an adjacent ledge on the side of the housing after the switch assembly is mounted. The horizontal surface may provide support for objects (e.g., cover glass and bezel beads) located above the installed switch assembly.

In certain embodiments, the ledge around the side may include a surface 154 for receiving the bezel bead 108 and the cover 106 across the cavity formed by the internal cavity. As described above, the cover 106 may be formed of a transparent material. When attached, the cover 106 may protect underlying components (e.g., a display) from damage. A partial side view showing the cover 106 and bezel bead 108 mounted to the housing is described in more detail with reference to fig. 7A and 7B.

Features (e.g., holes and/or grooves) may be formed in the ledges 156a, 156b, 156c, and 156 d. For example, two grooves 158 may be formed in the sidewall shelf 156d to allow the speaker assembly to be coupled with the enclosure. The recess may include holes to allow fasteners to be inserted to secure the speaker assembly. In another example, the recess 166 may be formed in a sidewall shelf 156d that provides a mounting point for the hall effect sensor 156 d. In yet another example, the sidewall shelf 156d may include a plurality of grooves (e.g., four grooves 168) that may extend to an upper surface of the sidewall shelf 156d and below the ledge 156 d. In one embodiment, the recess 168 may be configured to allow the magnet assembly to be mounted to the housing 102. The magnet assembly may be used to secure a cover device, which also includes a magnet, to the housing 102.

In one embodiment, a plurality of brackets may be coupled with the housing 102 to secure the housing in a particular area. For example, the data port opening 122 is relatively large, which may weaken the housing in the area around the opening 122. To stiffen the housing around the data port opening 122, a bracket 152 may be added over the opening. The bracket may be formed of a material such as metal. In one embodiment, the bracket may be configured to be attached to the housing such that it is aligned with the surface 154 for receiving the bezel bead. Thus, a portion of the bezel bead may be disposed on a bracket (e.g., bracket 152).

As another example, brackets 150a, 150b, 150c, and 150d may be located at each corner of housing 102. The corner brackets may be utilized to improve the ability of the device to resist impact damage (e.g., impact damage caused by the device falling on its corners). The impact damage may be reduced because the angle bracket increases the rigidity that may reduce deformation during an impact event. In one embodiment, the bracket may include a surface for receiving the bezel bead 108 in alignment with a surface for receiving the bezel bead formed in the side ledge. Further, when installed, the brackets may extend toward the interior of the housing to form ledges, similar to side ledges machined into the housing 102. More details of the corner bracket are described in more detail below with reference to fig. 4A and 4B.

Fig. 4A shows a perspective view of one corner 210 of the housing 102. In one embodiment, the SIM tray mechanism may be mounted in corner 210 to utilize openings 110a and 110B in the housing as shown in fig. 3B. One element 206 of the SIM tray mechanism is shown installed. The housing 102 may include an aperture 208. The holes may be used with fasteners to secure additional components associated with the SIM tray mechanism.

Corner bracket 150a extends around corner 210 to connect side ledge 156c and top wall shelf 156 a. The top ledge and sidewall shelf may be formed by cutting a portion of the shell blank from below during the machining process. Support brackets at lower heights may be formed below the height of the ledges 156c and 156a and the corner brackets. If desired, the support shelf may be cut at the lower portion, like the surrounding ledge. In the corner, the support bracket for the corner bracket 150a does not necessarily extend around the corner. The material may be removed to allow installation of components, such as the SIM tray mechanism 206.

In one embodiment, the corner brackets may be joined to the support brackets by using a liquid adhesive. Conductive foam may be located between the corner brackets and the support bracket to ground the metal brackets to the rest of the structure. Details of the engagement scheme and the laminated structure for the corner brackets are depicted in fig. 4B.

The use of the reinforced bracket is not limited to use around corners, and may also be used in other locations, such as between corners. For example, a portion of the ledge 156c may be removed to allow for mounting of the components. Brackets extending only along that side (as opposed to extending around the corner) can then be used to reform the ledge above the mounted element. The brackets may reinforce the housing in areas where ledge material is removed and replaced with brackets. In some embodiments, a portion of the ledge may be removed to form a void in the ledge, for example, to mount an element below the ledge. However, the void may be filled without the use of a bridging structure, and the housing may be used with a discrete ledge.

In one embodiment, the bracket 150a may be formed of a material such as stainless steel. The shape of the bracket may be selected to increase the strength of the housing in the area where it is mounted. By way of example, the bracket 150a may be castellated in the corner 210 to improve the ability to resist impact damage during a corner fall event. The castellations may include raised portions and depressed portions around the corners 210. The raised portion may add additional structure that may stiffen the bracket and distribute forces during a collision event. The number of castellations (i.e. the number of times the pattern of raising and lowering of the structure is repeated) may be varied. Thus, the example in fig. 4A is for purposes of illustration, and is not intended to be limiting.

To provide the castellation, the bracket 150a includes a ledge portion 204a that aligns with the ledge portion on the side ledge 156 c. Ledge portion 204a may be followed by a raised portion, a depressed portion, and another raised portion and a depressed portion 204b therebehind. The undercut portion 204b may be shaped to align with a ledge portion on the top edge 156 a. The castellated pattern may be specified in terms of local geometry (e.g., the local height and width of the elevated portions and depressed portions and the number of elevated portions and depressed portions). These parameters may vary between designs.

As previously described, the bezel bead 108 may extend approximately from the ledge portion on 156c to the ledge portion 204a on the bracket 150a, over the castellations, onto the ledge portion 204b and then onto the ledge portion of the top edge 156 a. In one embodiment, the shape of the perimeter frame bead may be modified to match the castellated pattern. For example, the border strip may be thinned where the structure is raised to form the castellations. In other embodiments, if the bezel bead can be sufficiently thin or formed of a compressible material, the thickness profile of the bezel bead can be unmodified to obtain a castellated pattern around the corners 210. For example, a bezel bead having a uniform thickness may be used over a feature having castellations near the corners 210.

Fig. 4B shows a side view 400 and a top view 416 of a stacked structure for joining a corner bracket to a housing, such as the one-piece housing 102 described above with reference to fig. 2 and 3. The bracket 402 may be joined to a support bracket 402 in the housing below with an adhesive. One or more pieces of conductive foam may be positioned between the support bracket 410 and the bracket 402 to ground the bracket to the rest of the housing. In one embodiment, the support shelf under the conductive foam may be laser etched to provide a good conductive surface.

The bracket 402 may be attached to the housing such that the top of the bracket is approximately level with the top of the adjacent structure 404. In one embodiment, to install the bracket, one or more pieces of conductive foam (e.g., two pieces of conductive foam) may be placed on the support frame and an adhesive path 420 may be set around the conductive foam. In one embodiment, the adhesive may be a liquid adhesive. In particular embodiments, the liquid adhesive may be an acrylic adhesive.

Next, the bracket 402 may be placed on top of the foam block and the fixture may be placed over the bracket. The fixture may be pressed down on the bracket 402 so that the bracket is mounted at a suitable height, for example approximately level with the adjacent structure 404. The conductive foam may be loaded when the fixture is depressed to push the bracket against the fixture to maintain the bracket at a desired height. The bond path 420 can be selected and laid under CNC control to wet the bottom surface of the bracket and spread out as the bracket is depressed, but does not extend into the area adjacent and below the conductive foam. The adhesive may be laid in such a way as to prevent the adhesive from spreading under the foam such that it interferes with the grounding capability of the conductive foam.

At 416, the support frame 410 is shown as a continuous structure. In other embodiments, a portion of the support frame may be removed. For example, a portion of the support frame may be removed such that two islands are formed in which each piece of conductive foam rests on a corresponding island. A bracket 402 may be coupled to each island.

Fig. 5A shows a perspective view 210 of one side of the housing 102 spanning the interior bottom surface of the housing and below the ledge 156c on the sidewall. Two recesses 214 may be formed below the ledge 156 c. Both recesses may include attachments, such as attachment points 212. In one embodiment, each recess may comprise two attachment points for attaching the device attachment component to the housing. The device attachment feature may be used to couple a device with the housing 102, such as a cover.

Fig. 5B shows a representation of an embodiment of a device attachment component 2400 attachable to housing 102. In particular, the attachment 2400 may include a magnetic element 2402/shunt 2404 attached with a leaf spring 2406. Leaf spring 2406 may be secured directly to shunt 2404 by fasteners 2408 and to end support 2410 by fasteners 2412. The end supports 2410 may be attached to a support structure (e.g., a housing) to provide support for the attachment member 2400. In one embodiment, alignment posts 2414 may be used to provide alignment for both the end supports 2410 and the leaf springs 2406 during assembly.

Fig. 6 shows a perspective view of one side of the housing 220 including a notch for the RF antenna window 132. The RF antenna window may be configured to support one or more antenna carriers within the window cavity. In one embodiment, the RF antenna window 132 may include a cavity 162 for supporting an image capture device and/or sensor assembly.

The housing 102 may include an approximately rectangular recessed portion in which the RF antenna window 132 is disposed. The bottom of the antenna tray 132 may be curved to conform to the exterior of the housing (see fig. 2). In one embodiment, the antenna tray may be supported by a support wall 226 formed in the housing 102. The RF antenna window 132 may include a lip 222 that overhangs a support wall 226. The lip 222 may help prevent the antenna tray from being pulled out of the housing. The RF antenna window 132 may be bonded to the housing with a liquid adhesive. The antenna tray 132 may be engaged along the lip and the outward facing surface of the support wall 226.

The support wall 226 may include a plurality of openings, such as opening 224. The opening 224 may be aligned with an opening in the RF antenna window 132. The opening may allow wires to pass through the housing and into the antenna carrier to reach elements in the RF antenna window 132, such as one or more antennas and image capture and/or sensor components.

In an alternative embodiment, the RF antenna window 132 and its associated antenna may be removed. In this embodiment, the exterior and interior of the housing where the support wall 226 is removable and proximate the antenna location may be formed of the same material as the rest of the housing, such as a single metal blank. If an image capture device is included at the location shown in fig. 6, the image capture device components may be attached directly to the housing 102, rather than the RF antenna window. The image capture device assembly (not shown) may be mounted on top of the compressible foam. The thickness of the compressible foam may be selected so that the image capture device assembly is jogged to the cover glass when the cover glass is installed. This force may help to ensure that the image capture device assembly is properly aligned with the cover glass.

Fig. 7A and 7B illustrate a side view showing a mechanism for coupling the cover with the housing. The ledge may be formed at an upper portion of the housing sidewall. The ledge may include a surface for receiving the bezel bead 108. Thus, the bezel bead 108 (which may be a gasket formed of an elastomeric material) may rest against the ledge of the housing. As described above with reference to fig. 4, the bezel bead 108 may be disposed on top of a bracket (e.g., a corner bracket) attached to the housing at a plurality of locations. The bezel bead 108 may be joined to the housing through the use of an adhesive 230a (e.g., epoxy or PSA tape). The cover 106 may then be joined to the bezel bead 108 around the perimeter of the housing using an adhesive (e.g., 230 b). The bezel bead 108 may help form a seal to the interior of the housing. The seal may help prevent external contaminants (e.g., moisture) that may damage the internal components from entering the interior of the housing. In addition, the bezel bead 108 can lift the cover 106 so that it does not contact the housing 102, thus providing a cushion between the housing and the cover 16, which can prevent damage to the cover caused by a collision of the housing with the cover. In one embodiment, the top of the cover glass 106 may extend slightly 232 about the top height of the bezel bead 108.

Structures (e.g., 234) may be located below the cover 106. The structure 234 may be associated with a component (e.g., a display assembly) located beneath the cover 106. Comparing fig. 7A and 7B, it can be seen that the amount of underlying structure proximate to the bezel bead 108 can vary. For example, in comparison to FIG. 7A, FIG. 7B illustrates a larger gap 236 between the bezel bead 108 and the underlying structure. In certain embodiments, when a void (e.g., 236) is present, the adhesive 230b (e.g., PSA tape) can extend from between the bezel bead 108 and the cover 106 to under the cover 106 where portions of the PSA tape are joined to the cover glass but not to the underlying surface (e.g., bezel bead 108), which can provide cushioning to the cover 106 during a crash event.

In this example, the extended adhesive 230b may serve as a safety measure if the cover 106 is broken during a collision event. Cover 106 may be formed from a glass material that may be broken into pieces. The extended adhesive 230b may hold the pieces of broken cover together so that small pieces do not become dislodged from the device during a collision event. Thus, the extended adhesive 230b may perform a function similar to safety glass, which may include a reinforcing element that provides limited structural integrity to ensure that the glass does not fly apart in the event of a collision.

Fig. 8 shows a side view of logo laminated structure 250. The housing 102 may include an opening 260, and the opening 260 may be shaped in the shape of a symbol (e.g., a logo). In one embodiment, the thickness of the housing 102 in the area around the emblem may be less than about 1 millimeter. In particular embodiments, the housing thickness may be about 0.78 millimeters. Material may be removed from the bottom interior surface of the housing such that a ledge is formed that includes sides 258a and 258 b. The ledge may provide a surface for attaching the logo-laminating structure 250 to the housing 102.

In one embodiment, the insert 256 may be configured to fit within the opening. The insert may be formed of a material such as plastic. The logo insert may be thinner than the nominal thickness of the perimeter housing. In one embodiment, the logo insert may be about 0.59 millimeters thick.

In particular embodiments, the insert may be opaque to light, such as painted black, or formed of an opaque material. In other embodiments, the insert may be formed of a translucent material. In one embodiment, the translucent material may be configured to diffuse light from the internal light source such that the logo appears illuminated when viewed from the outside.

The logo insert 256 may be bonded to the support structure 252 using an adhesive 254. In particular embodiments, the adhesive may be a tape, such as a Pressure Sensitive Adhesive (PSA) tape or an epoxy, and the support structure may be formed from a metal sheet material (e.g., a stainless steel sheet material). The metal may be shaped such that it fits around a ledge formed in the housing 102. The support structure 252 may be bonded to the ledge using an adhesive (e.g., PSA or epoxy).

In one embodiment, conductive strips may be used to ground the support structure 252 to the housing, such as conductive strips located over a portion of the housing and a portion of the support structure. In another embodiment, a conductive adhesive may be used to couple the support structure 252 with the housing 102, wherein the conductive adhesive mechanically attaches and grounds the support structure to the housing. In an alternative embodiment, a single piece structure (e.g., a single piece of molded plastic) may be used rather than utilizing separate support structure 252 and logo insert 256.

After the logo is installed, a top layer may be added on the inside of the housing. For example, the top of the stainless steel sheet may be coated in some way. In one embodiment, the layer may be deposited using an electrophoretic deposition process.

The logo-laminated structure 250 may be part of a fire-resistant enclosure associated with the housing 102. The fire resistant enclosure may be configured to include an exothermic event generated within the interior of the enclosure, such as an exothermic event associated with the battery. The metal support structure 252 coupled with the logo insert 256 may help contain internal exothermic events.

As described above, the support structure 252 and the logo insert 256 may be formed as a single piece. In one embodiment, the single piece may be formed of metal. Metals may be suitable for use as part of a fire resistant enclosure. However, a decorative layer may be applied to a portion of the emblem insert 256. In another embodiment, the single piece may be formed from a plastic material. If desired, a flame retardant film may be applied over the logo insert 256 in the interior of the housing 102 in order to improve its fire-blocking capability.

Fig. 9 illustrates a method 300 of forming a housing for a portable device. In one embodiment, the housing may be formed from a single metal blank (e.g., an aluminum blank). In particular embodiments, the blank may be provided as a rectangular sheet of material having a nominal thickness of about 11 millimeters, wherein about 90% or more of the blank is removed during the machining process. After processing, the thickness of the shell may be less than 1 cm.

In 302, a CNC cutting path for removing material may be determined that allows for a final housing shape to be formed. The processing path may be optimized to minimize processing time and improve throughput. At 304, the blank may be machined to form the outer shape of the shell. As described above, in certain embodiments, the exterior shape may form the bottom of the device. Typically, the outer shape and the inner shape of the housing may be separately machined using different processes.

At 306, machining to form the internal shape of the housing may begin. Initial machining may include removing a large interior portion of the housing within its center to form a somewhat rectangular shaped cavity. After the bulk processing is performed, finer processing can begin in 308. For example, a ledge for supporting the cover may be formed around the outer top. The ledge may be formed by cutting from below into the billet side face using a suitable machining tool, such as a drill bit having a right angle. The top ledge may be machined to include a surface for receiving a bezel bead (see 108).

Machining may include guiding a tool over a particular 3-dimensional path. In one embodiment, the local relative dimensions may be utilized to guide the path of the machining bit. The use of a local relative dimension, as opposed to an absolute position associated with the fixture or another non-local dimension associated with the housing, may include determining a path from a reference point on the housing as the housing is being processed. For example, when an undercut is created into the sidewall, the local thickness dimension of the sidewall, as opposed to the distance from the housing centerline, may be used to determine a machining path for the cutting tool such that the desired sidewall thickness is maintained. This process may be repeated at different locations of the housing when different cuts are made. For example, when machining a ledge for a logo where the shell thickness is relatively thin, the local thickness of the shell at that location may be used to guide the machining process. Machining tolerances can be reduced by using local relative dimensions, which can be important to ensure that the cut (e.g., of the side walls) does not result in a housing that is too thin in certain areas.

At 312, internal attachment and/or alignment points may be formed. The internal attachment points may be formed as holes in the housing. In certain embodiments, the aperture may be formed as a raised cylinder or "bump" in the housing material. In other embodiments, a recess may be formed in the housing that is configured to receive an apertured attachment element, such as an aperture aligned along a wire, which may serve as an attachment point. The additional element may be attached to the housing by using an adhesive. The holes may be configured to receive fasteners, such as screws. The attachment point may be used to secure components such as, but not limited to, a display assembly, a speaker, a SIM tray mechanism, and a PCB.

The alignment points may be cavities, holes or markings that may be used during the assembly process. For example, the housing may include a recess configured to receive a portion of the alignment fixture. The alignment fixture may be used to align the components by mounting one portion of the alignment fixture into a recess in the housing and another portion into a recess in the component. The element can then be moved relative to the housing until it is aligned at the point where it can be secured. In one embodiment, a recess may be provided in the housing and a recess may be provided in the display assembly that may be used with the alignment fixture to align the display assembly relative to the housing.

At 312, processing may include removing excess material from the housing. Excess material may be removed from various locations (e.g., below ledges formed in the housing) to reduce the weight of the housing. At 314, an interior-to-exterior gap may be formed in the housing. For example, openings for data ports, SIM card trays, volume switches, slide switches, power switches, and audio jacks may be formed. In one embodiment, the opening can be formed by machining in a direction orthogonal to the shape of the outer surface.

In one embodiment, a large number of small holes may be formed in the housing to provide an outlet for sound generated by one or more internal speakers. The holes may be formed by a piercing tool that punches one or more holes at a time. In one embodiment, the aperture may be punched from the exterior of the housing to the interior along the curved side of the housing. The hole may be stamped in a surface of varying curvature, such as a side wall of the housing. The fixture may be used to rotate the housing so that the hole may be punched approximately orthogonal to the curvature of the outer surface, or the cut-out may be made at some other desired angle.

In certain embodiments, a bracket may be coupled with the housing to locally enhance the structural integrity of the housing. For example, a bracket may be mounted near the opening of the data port on the side of the housing. The opening of the data port is relatively large and the housing may be thin where the data port is provided. A larger opening may reduce the strength of the housing. Therefore, a support bracket may be added near the opening of the data port. The support bracket may be bonded to the housing using a bonding agent (e.g., a liquid adhesive) and may be grounded to the housing. In various embodiments, the metal bracket may be grounded to the housing through the use of conductive foam or tape.

In another embodiment, support brackets may be added in the corners of the housing. The support bracket may add additional strength, which improves the drop test performance of the housing. In one embodiment, the corner brackets may include a castellated pattern to increase their strength. As previously described, a ledge may be formed around the housing to support the cover. Near the corners, it may be desirable to remove material forming the ledge in the corner regions. The ledge material may be removed so that the mechanism may be installed in a corner. For example, as described above with reference to fig. 4, the SIM tray mechanism is mounted in a corner of the housing. After the mechanism is installed in the corner from which the ledge has been removed, the corner brackets may be attached to form a ledge that is flush with the ledge formed on the other part of the housing. The bezel bead and subsequently the cover may be attached in this corner using a ledge formed by the corner bracket.

In 318, an RF antenna window may be added to the housing. The RF antenna window may be formed of a radio transparent material (e.g., plastic). The antenna carrier may be located near an edge of the housing. It may be shaped such that it forms part of the continuous exterior of the housing. The RF antenna window may be used to install one or more antennas for receiving wireless data, such as data received from a cellular data network. At 320, additional components (e.g., a battery, a main logic board, a display assembly, a bezel trim strip, and a cover) may be attached to the housing until the final assembled configuration is completed.

Fig. 10 is a block diagram of an arrangement 900 of functional modules utilized by an electronic device. The electronic device may be, for example, a tablet device 100. The arrangement 900 includes an electronic device 902 that is capable of outputting media to a user of the portable media device and is also capable of utilizing a data store 904 to store and retrieve data. The arrangement 900 also includes a Graphical User Interface (GUI) manager 906. The GUI manager 906 operates to control information provided to and displayed on the display device. The arrangement 900 also includes a communication module 908 that facilitates communication between the portable media device and the accessory device. Further, the arrangement 900 includes an accessory manager 910 that operates to authenticate and acquire data from accessory devices that may be coupled with the portable media device.

FIG. 11 is a block diagram of an electronic device 950 suitable for use with the described embodiments. The electronic device 950 illustrates circuitry of a representative portable media device. The electronic device 950 may include a processor 952, which may be a microprocessor or controller, for controlling overall operation of the electronic device 950. The electronic device 950 may be configured to store media data pertaining to media items in a file system 954 as well as a cache 956. The file system 954 may be implemented using a memory device, such as a storage disk, a plurality of disks, or solid state memory (e.g., flash memory).

The file system 954 may typically be configured to provide mass storage capability for the electronic device 950. However, to improve access time to the file system 954, the electronic device 950 may also include a cache 956. The cache 956 may be, for example, a Random Access Memory (RAM) provided by a semiconductor memory. The relative access time to the cache 956 (e.g., a RAM cache) may be much shorter than other memory (e.g., flash or disk memory). The cache 956 and the file system 954 may be used in conjunction, as the cache 956 may not have the large storage capacity of the file system 954, as well as the non-volatile storage capabilities provided by the storage device hosting the file system 954.

Another advantage of using a cache 956 in conjunction with the file system 954 is that the file system 954, when active, consumes more power than the cache 956. The use of the cache 956 may reduce the active time of the file system 954 and thus reduce the overall power consumed by the electronic device. Power consumption is typically a concern when the electronic device 950 is a portable media device that is powered by a battery 974.

The electronic device 950 may also include other types of memory devices. For example, the electronic device 950 may also include RAM 970 and Read Only Memory (ROM) 972. In particular embodiments, ROM 972 may store programs, common programs, or processes to be executed in a non-volatile manner. The RAM 970 can be used to provide volatile data storage, such as for the cache 956.

Electronic device 950 may include one or more user input devices (e.g., inputs 958) that allow a user of electronic device 950 to interact with electronic device 950. The input device (e.g., 958) may take various forms, such as buttons, a keyboard, a dialer, a touch screen, an audio input interface, a video/image capture input interface, input in the form of sensor data, and so forth. Further, the electronic device 950 includes a display 960 (display screen) that may be controlled by the processor 952 to display information to a user. The data bus 966 can facilitate data transfer between at least the file system 954, the cache 956, the processor 952, and the CODEC 963.

In one embodiment, the electronic device 950 is used to store a plurality of media items (e.g., songs, podcasts, image files, video files, etc.) in the file system 954. The media items (media assets) can belong to one or more different types of media content. In one embodiment, the media items are audio tracks (e.g., songs, audio books, and podcasts). In another embodiment, the media item is an image (e.g., a photograph). However, in other embodiments, the media items may be any combination of audio, graphical, or video content.

When a user wishes to have the electronic device play a particular media item, a list of available media items is displayed on the display 960. The user may then select one of the available media items using one or more user input devices (e.g., 958). The processor 952, upon receiving a selection of a particular media item, provides media data (e.g., an audio file) for the particular media item to one or more coder/decoders (CODECs), e.g., 963. The CODEC (e.g., 963) may be configured to generate output signals for an output device (e.g., speaker 954 or display 960). The speaker 964 may be a speaker internal to the media player 950 or external to the electronic device 950. For example, headphones or earphones that connect to the electronic device 950 would be considered an external speaker.

The electronic device 950 may be configured to execute a plurality of applications in addition to the media playback application. For example, the electronic device 950 may be configured to execute communication applications such as voice, text, email, or video conferencing applications, gaming applications, web browsing applications, and many other types of applications. A user may select one or more applications for execution on electronic device 950 using an input device (e.g., 958).

Electronic device 950 may include an interface 961 coupled to data link 962. The data link 962 allows the electronic device 950 to be coupled to a host computer or an accessory device. The data link 962 may be provided by a wired connection or a wireless connection. In the case of a wireless connection, interface 961 may include a wireless transceiver. Sensor 976 may take the form of a circuit for detecting any number of stimuli. For example, sensors 976 may include hall effect sensors responsive to external magnetic fields, audio sensors, light sensors (e.g., photometers), gyroscopes, and the like.

Fig. 12 shows a perspective view 2200 of the antenna window 132 mounted to the housing 102 from a different perspective than that shown in fig. 3B. As described above, the RF antenna window may be configured to support one or more antenna carriers within the cavity of the window. As described above, the RF antenna window 132 may optionally include a cavity 2162 for supporting an image capture device and/or sensor assembly.

The housing 102 may include a recessed portion in which the RF antenna window 132 is disposed. In one embodiment, the antenna window 132 may be supported by a support wall 2170 formed in the housing 102. The RF antenna window 132 may include a lip 2166 depending from the support wall 2170. The lip 2166 may help prevent the antenna tray from being pulled out of the housing. The RF antenna window 132 may be attached to the housing with an adhesive, such as epoxy or PSA tape. The antenna tray 132 may be engaged along the lip and the outward facing surface of the support wall 2170.

The support wall 2170 may include a plurality of openings, such as openings 2168. The opening 2168 may be aligned with an opening in the RF antenna window 132. The opening may allow wires to pass through the housing into the antenna carrier to reach elements in the RF antenna window 132, such as one or more antennas and image capture and/or sensor components. In an alternative embodiment, the RF antenna window 132 and its associated antenna may be removed. In this embodiment, the exterior and interior of the housing where the support wall 2170 is removable to access the antenna location may be formed of the same material as the rest of the housing.

Fig. 13A-13C show side views of the antenna laminate structure that allow the antenna to be mounted to the bottom of cover glass 106. In fig. 13A, an antenna 2174 is mounted to a first surface portion of an antenna carrier 2136. The antenna 2174 may be mounted to the antenna carrier 2136 by use of an adhesive layer 2172b (e.g., PSA tape or epoxy). In one embodiment, the antenna carrier 2136 may be shaped to fit in a particular space available in the housing. For example, in one embodiment, the antenna carrier may be shaped to fit within a cavity (e.g., 2160a or 2160b) associated with the RF antenna window 132.

In certain embodiments, a piece of compressible foam 2178 may be attached to the second surface portion of the antenna carrier 2136 through the use of an adhesive layer (e.g., 2176). The adhesive layer 2176 may be formed of a bonding agent such as a PSA tape or liquid epoxy. After compressible foam 2178 is secured to the antenna carrier, antenna carrier 2136 may be located in a space (e.g., a space in RF antenna window 132).

In one embodiment, adhesive layer 2172a may be provided with a protective film (not shown) to prevent objects from sticking to the top of cover 106 before it is secured to antenna laminate structure 2202. Cover glass 106 and antenna 2174 may be aligned with each other and the film may be removed to attach the antenna to the cover glass.

When the cover 106 is lowered into place, the adhesive layer 2172a may engage the antenna 2174 to the bottom surface of the cover. The overall stacked structure may be configured such that the top height of the stacked structure 2202 is higher than the height 2177 at which the bottom of the cover 106 is secured. Thus, when cover glass 106 is secured in place, the cover glass may exert a downward force on the laminated structure. This downward force may cause the height of foam 2178 to decrease such that the foam exerts a force against the bottom of cover 106.

The upward force exerted by the foam 2178 may push the adhesive layer 2172a toward the cover bottom and may help minimize the air gap that may form between the adhesive layer 2172a and the cover 106. The air gap may affect the performance of the antenna. Thus, minimizing the air gap between the bottom of cover 106 and adhesive layer 2172a may help prevent variations in antenna performance between devices that may result from the presence of an air gap between the antenna and the cover glass.

The compressible foam described herein may include air cells and cavities commonly referred to as honeycombs (cells). Depending on the structure and formulation of the honeycomb, the honeycomb may be described as an "open cell", "semi-open cell", and "closed cell". The foam element can be used in many different positions in the housing. In different embodiments, the foam formulation used, the shape of the foam elements and their thickness may vary from location to location.

If the foam is compressed beyond a certain percentage of its original size, for example to less than or greater than 20% of its original size, the force exerted by the foam may increase significantly. The compression limit at which the force begins to increase significantly may be approximated as all cells become closed as a result of compression. The compression limit at which the force begins to increase significantly may vary between foam types after the foam is compressed beyond a certain limit. However, the foam may be sized so that this limit is not reached when the cover is engaged in position over the foam.

In alternative embodiments, other mechanisms may be used to push the antenna toward the cover glass bottom or some other desired surface, in addition to or in conjunction with the use of compressible foam, to help form a good seal. Generally, there are mechanisms that may use different configurations of the forcing element, such as a "spring-like" element, to achieve this goal of pushing the antenna toward the cover glass. By way of example, in various embodiments, the mechanism may include the use of cantilevered springs, coiled geometry, or inflatable pillows. Furthermore, if multiple antennas are mounted in this manner, the mechanism for urging the antennas toward the desired surface may vary between different positions.

For antenna uniformity, it may be desirable to have a certain amount of force to push against the antenna during the process of bonding to the cover glass. As described above, a force applying mechanism (e.g., a compressible foam) may be used to apply the force. However, after the antenna is joined to the cover glass and the cover glass is fixed to the case, it is undesirable to push the antenna and the cover glass with excessive force because the force pushing on the cover via the antenna may reduce the adhesion between the cover glass and the case, resulting in a reliability problem.

To prevent excessive forces from being generated after the cover glass is attached to the housing, a nominal force may be selected that takes into account the variation in force that can occur due to assembly tolerances, wherein in the worst case sufficient force is still provided to the antenna to meet the minimum force requirements needed to generate the desired antenna performance. In the case of foam, assembly tolerances may result in a greater or lesser amount of foam compression and a greater or lesser amount of force exerted by the foam on the antenna. To provide a nominal force with the foam, a foam thickness may be selected in which the amount of compression expected to be applied to the foam is far from the full compression limit and the variation in foam thickness caused by assembly tolerances is small relative to the overall foam thickness.

In an alternative embodiment, a force applying mechanism may be provided that applies a nominal force to the antenna during engagement of the antenna to the cover glass, but the nominal force provided by the force applying mechanism is reduced or eliminated after the antenna is engaged to the cover glass, for example when the cover glass is secured to the housing. As an example, mechanical snaps may be used on the antenna carrier. The mechanical snaps may be configured to push the antenna carrier and antenna toward the glass with a particular force profile, but then to jump into place after the cover glass reaches its installed position. After the jump is in place, the force applied by the mechanical snaps may be reduced or eliminated.

In another example, a friction mounting process may be used. The antenna carrier may be configured to interfere with the space in which it is to be installed. For example, the antenna carrier may include features such as protrusions, cavities, or rubber gaskets that may create interference with the surrounding space in which it is to be installed. During installation, the antenna carrier may be located near the space where it is to be installed, and then the cover glass may be pushed towards the antenna and the antenna carrier. When the antenna carrier is pushed into its mounted position, the friction generated by the interference provides a resistance to pushing the antenna carrier and the antenna towards the cover glass. After the antenna carrier reaches its final position, the force exerted by the antenna carrier may be reduced or eliminated.

In yet another example, a semi-rigid, deformable material may be disposed beneath the antenna carrier, such as putty or wax. When the antenna carrier is pushed into the deformable material, a nominal force required to engage the antenna to the glass may be generated. After deformation, the deformable material may be placed in its deformed shape so that it is not (or with little force) pushed against the glass after it is secured in place.

An alternative antenna stack-up structure 2204 is shown in fig. 13B. In this embodiment, proximity sensor 2182 is bonded to foam layer 2178. Further, a shield layer 2180 (e.g., a metal shield layer) is disposed between the proximity sensor 2182 and the antenna 2174. In one embodiment, the shielding layer may be formed of a metal film. In this embodiment, the shielding layer may not be grounded. The shield layer 2180 may help prevent the antenna 2174 from receiving signals generated by the proximity sensor 2182. In another embodiment, the shield layer may be grounded to the metal portion of the housing.

In one embodiment, the shield layer 2180 may be disposed between the foam 2178 and the antenna carrier 2136 via adhesive layers 2176a and 2176 b. In other embodiments, the shielding layer 2180 may be disposed at other positions. For example, the shield layer 2180 may be built into the antenna carrier 2136.

A proximity sensor may be used to detect whether an object (e.g., a human hand) is proximate to the RF antenna window 132. The portable device may be configured to provide a variable amount of power to the antenna 2174, thus affecting the strength of the signal transmitted by the antenna 2174. In one embodiment, when an object or surface is detected in proximity to the proximity sensor, the portable device may be configured to reduce the amount of power supplied to the antenna 2174. In another embodiment, if the device includes multiple antennas, a proximity sensor may be provided for each antenna, and the amount of power supplied to each antenna may be adjusted for the antenna on an antenna-by-antenna basis. Thus, in some embodiments, if an object is detected in proximity to one antenna and not another, power to one antenna but not the other may be reduced. In other embodiments, when an object is detected proximate to one antenna or the other, power to both antennas may be reduced.

Another antenna stack-up structure 2206 is shown in fig. 13C. In this embodiment, antenna 2174 is attached to foam 2178 via adhesive layer 2172 b. The foam 2178 is then bonded to the underlying support structure 2184 via the adhesive layer 2182. Foam 2178 may help create a good seal with minimal air gaps between antenna 2174 and cover 106. As described in more detail with reference to fig. 13A and 13B, a laminated structure of an antenna and foam (e.g., 2206) may be joined to the speaker assembly.

The configuration of the antenna laminated structure is described with reference to fig. 14, 15A, and 15B, in which the antenna is fixed to the bottom of the cover glass near the position where the cover glass is attached to the case. Thus, mounting the cover glass to the housing is generally described with reference to fig. 14. The housing and the means for attaching the cover glass to the housing may be modified when the antenna is mounted proximate to where the cover glass is attached to the housing. In certain embodiments, details of these modifications are described with reference to fig. 6A and 6B.

Fig. 14 illustrates a side view of a laminate structure 2208 for coupling the cover 106 to the housing 102. The housing 102 may include a surface for receiving the bezel bead 108. The bezel bead 108 may be mounted to the housing through the use of an adhesive layer (e.g., 2188 a). In one embodiment, the bezel bead 108 may be disposed around the periphery of the housing 102. In embodiments using an antenna window, a portion of the bezel bead 108 may extend over the antenna window. The cover 106 may be joined to the bezel bead 108 via an adhesive layer (e.g., 2188 b). When the cover 106 is installed, it may enclose underlying structures (e.g., 2190), which may be associated with various device elements.

Fig. 15A shows a perspective view of the antenna stack-up located near the outer edge of the housing 102. In one embodiment, the antenna 2194 may be part of an antenna laminate structure, including a compressible foam material as described above with reference to fig. 13C. In one embodiment, the antenna stack may be mounted to a speaker assembly 2210. The antenna may include an alignment hole 2220 that may be used to align the antenna 2194 with the cover glass. An antenna 2194 may be coupled to a conductor 2192 that allows information to be transferred between the antenna and a logic board (e.g., a host logic board on the device). The information may be associated with a signal received by the antenna 2194 or a signal to be broadcast through the antenna. In one embodiment, the antenna 2194 may be used to implement a wireless protocol, such as Wi-Fi.

To improve wireless performance, it may be desirable to place the antenna near the edge of the housing. If the housing is formed of a radio opaque material (e.g., metal), it may be desirable to make the housing 102 as thin as possible near the antenna while maintaining a relatively uniform metal thickness near the antenna in order to improve antenna performance. In fig. 15A, an antenna 2194 may be mounted on the housing 102 proximate one edge of the housing between the corner bracket 2150c and the support bracket 2152 (see fig. 3B). In other embodiments, the antenna 2194 may be mounted in other locations near the housing. Further, the antenna 2194 may be mounted on top of the speaker assembly or on top of some other internal structure. Accordingly, this example is provided for illustrative purposes only and is not intended to be limiting.

In fig. 15A, the bezel bead 108 includes a notched portion. The notched portion allows the ground pad 2198 to be grounded to the housing 102 near the antenna 2194. The ground plate 2198 may be secured to the housing 102 via one or more fasteners (e.g., fasteners 2196). In one embodiment, a cover layer (not shown) may be placed over the fasteners after ground pad 2198 is secured to the housing. As described above, in order to improve the antenna performance, it may be desirable to thin the housing 102 in the vicinity of the antenna 2194. This characteristic is illustrated below with reference to fig. 15B.

In fig. 15B, the support bracket 2152 is removed to show the underlying structure of the housing. The housing 102 includes a ledge 2102a for receiving the bezel trim 108. Another ledge 2102b is adjacent to the ledge 2102 a. The ledge 2102b is configured to receive a support bracket 2152 as shown in fig. 15A. Ledge 2102b is positioned below ledge 2102a such that when support bracket 2152 is placed on ledge 2102b, the top of the support bracket is at approximately the same height as ledge 2102 a. The bezel molding 108 may then rest across the top surfaces of the bracket 2150c, the bracket 2152, and the ledge 2102 a.

In fig. 15B, the distance between side 2194a and the outer edge of the housing is approximately the distance between locations 2102d and 2102e on the housing. This distance is about the thickness of the housing at this location. The thickness of the housing is relatively constant along the side 2194a of the antenna 2194 and is approximately the thickness of the housing between the positions 2102d and 2102 e. In fig. 15B, it can be seen at position 2102c on ledge 2102B that the housing is thicker at this position relative to the thickness of the housing along 2194a, i.e. position 2102d is closer to the edge of the housing than position 2102 c. As described above, providing a relatively thin housing with a constant thickness near the antenna can help improve antenna performance.

Fig. 16 is a perspective view of a speaker assembly 2210. As described above, in one embodiment, the antenna stack may be mounted on top of the speaker assembly 2210. For example, the antenna may be mounted to the speaker assembly near location 2232. The speaker assembly 2210 may include a housing 2224 and a connector 2234 that allow the speaker to receive signals that are converted to sound. The housing 2224 may enclose one or more speaker drivers. In one embodiment, the housing 2224 may enclose two speaker drivers.

One concern when mounting an antenna (e.g., 2194 in fig. 15A) is that the magnets in the speaker driver may generate EMI, which may affect antenna performance. In one embodiment, to mitigate possible EMI from the speaker drivers, each driver may be grounded to a metal portion of the housing 2224. For example, a first driver may be grounded to the metal portion 2222 in the housing 2224, while a second driver may be grounded to the metal portion 2226 in the housing 2224. As such, a conductive material (e.g., a conductive tape) may be coupled to each metal portion and wrapped around housing 2224 such that a faraday cage is formed around each speaker driver. For example, the conductive strip 2234 is coupled to the metal portion 2222 and wound around the housing 2224, and the conductive strip 2228 is coupled to the metal portion 2226 and wound around the housing 2224. A faraday cage is thus formed around each of the two drivers. Finally, conductive straps (e.g., 2224 and 2228) used to form the faraday cage can be grounded to the housing.

In addition, the use of conductive tape may provide other advantages. For example, a speaker assembly may include metal elements that vary in size, shape, and their mounting location in the assembly. These variations can affect antenna performance depending on the mounting position of the antenna relative to the metal element. The conductive strip may provide a constant ground plane between the antenna and the metallic element, which may help mitigate any effects due to variations in size, shape, and location of the metallic element of the speaker assembly relative to the antenna. Another example of the advantages that may be brought about by the use of conductive strips is that conductive strips may be used to fill voids and openings between metal objects that may resonate at radio frequencies that degrade antenna performance.

As described above, grounding may be important to maintain consistent antenna performance. In addition, other components may be sensitive to EMI and a good grounding scheme may help mitigate EMI issues. One element that may be sensitive to EMI is a touch panel, such as a capacitive touch sensor. The touch panel may be located on a display module, such as a display module including an LCD display. Some details regarding grounding the display module to mitigate EMI issues associated with the touch panel being proximate to the display module, and grounding the display module to mitigate EMI issues associated with the display module being proximate to the one or more antennas are described in more detail below.

To meet the overall thickness goals of the portable computing device, it may be desirable to minimize the thickness of the various device elements. For example, a display module without a bezel may be used to make the display module thinner. As another example, for portable devices having a touch panel, the touch panel may be disposed in relative proximity to a display element associated with the display module (e.g., an LCD glass associated with an LCD display). In a particular embodiment, the touch panel layer may be located a distance of less than 1 millimeter from the EMI generating layer in the display module. The EMI generating layer or layers in the display module may vary depending on the display technology used, and examples of the LCD glass are provided for illustrative purposes only.

As described above, the EMI generating layer or layers in the display module may be grounded to mitigate the effects of EMI on the touch panel. In the case of a display module, it is desirable to make such grounding while not increasing, or at least increasing a minimum amount of thickness to the display module. To achieve this, in one embodiment, conductive tape may be used to ground the EMI generating display circuitry in the display module to the metal portion of the display module housing, for example, to ground the thin film traces on the LCD glass to the metal portion of the housing. In a particular embodiment, the thin film traces can be ITO traces.

The conductive strip may have a thickness of less than 0.1 mm. In a particular embodiment, the conductive strips may be about 0.06 millimeters thick. The conductive tape may use an adhesive that does not attack or damage the substrate to which it is bonded in any way, such as a film formed on LCD glass. The conductive tape may be formed with an cosmetically acceptable color. For example, in one embodiment, the visible portion of the conductive strip may be "black" in color.

Embodiments of grounding schemes for display modules are described below. Fig. 17 shows a side view of a layered structure 2212 for providing imaging services and touch recognition capabilities. The display module 2242 may be disposed under the cover glass 106. The touch panel 2246 may be located above the display module 2242. A layer of conductive strip 2244 may be provided to ground display circuitry (e.g., a film with circuit traces on LCD glass) that may affect EMI generation in the display module 2242 of the touch panel 2246. In one embodiment, a dust protective layer 2240 may be disposed above the conductive strip 2244 and below the cover 106.

In a particular embodiment, one end of the conductive strip 2244 may be coupled with one or more layers of EMI generating display circuitry in the display module 2242 (e.g., a film with circuit traces on LCD glass). The conductive strip 244 may then be attached to a metal portion of the housing for the display module 2242. For example, if metal portions of the housing extend to the sides of the display module 2242, conductive strips may extend over the top of the display 2244 and partially around the sides, and attached to the metal portions on the sides. If the metal section is located at the bottom of the display module 2242 and does not extend around the sides, the conductive strip may extend over the top of the display module 244, around the sides, and partially onto the bottom of the display module. One advantage of using a layer of conductive tape (e.g., 244) is that it can be thinner than using a corresponding metal structure for grounding purposes.

To control interference and antenna resonance between display circuitry associated with the display module 2242 and one or more antennas, a metal chassis (chassis) of the display module may be grounded to the ground plane of the antennas. In one embodiment, the grounding may be achieved by: a slot is cut in the conductive strip (e.g., 2244) associated with the display module 2242, a conductive foam is adhered to the display module 2242 proximate the slot and then compressed into the void where the foam may contact the conductive surface associated with the ground plane of the antenna. The foam may be compressed in this manner during installation of the display module 2242. In certain embodiments, foam may be used at multiple locations to ensure good grounding between the display module and the antenna ground plane.

Fig. 18A illustrates a method of generating an antenna stack structure for a portable device. In 2302, the shape and size of the antenna may be determined. The shape and size may be based on factors such as packaging limitations and wireless performance considerations, for example. In 2304, an antenna may be engaged to the compressible foam. A bonding agent, such as a Pressure Sensitive Adhesive (PSA), may be used to bond the antenna to the foam. In 2306, the foam may be engaged to an underlying support structure. In one embodiment, the foam may be joined to a support structure associated with the speaker assembly, as described above with reference to fig. 13C.

In 2308, the antenna can be aligned with a cover (e.g., a cover glass for a portable electronic device). The cover glass may be transparent to both visible light and radio waves. In one embodiment, the antenna assembly may include an alignment hole for receiving an alignment point on the cover. The cover glass and antenna may be aligned as part of the attachment of the cover to the housing. At 2310, an antenna may be coupled to the cover. The antenna may be attached to the cover by using an adhesive, such as a PSA tape.

The foam may be sized such that the foam is compressed when the antenna is disposed against the cover. The compression of the foam may exert a force that presses the antenna toward the bottom of the cover. The pressure exerted by the foam may help form a good seal between the cover and the antenna, such as a seal in which the air gap between the antenna and the cover is minimized and is relatively constant across the interface between the antenna and the cover (i.e., air bubbles affecting the performance of the antenna are minimized).

If the foam is compressed beyond a certain percentage of its original size, for example to less than or greater than 20% of its original size, the force exerted by the foam may increase significantly. This limit is reached when all open cells of the foam are compressed. The compression limit at which the force begins to increase significantly may vary between foam types after the foam is compressed beyond a certain limit. However, the foam may be sized so that this limit is not reached when the cover is engaged in position over the foam.

Fig. 18B illustrates another embodiment of a method of producing an antenna stack structure for a portable device. At 2312, the size and shape of the antenna may be determined. At 2314, an antenna may be engaged to one side of the antenna carrier (see, e.g., 2136 in fig. 13A and 13B). The shape of the antenna may vary. Typically, the shape is selectable to fit within a specified space in the housing, which may vary.

At 2314, an antenna may be bonded to one surface portion of the antenna carrier. At 2316, a compressible foam (e.g., an open cell foam) may be bonded to another surface portion of the antenna carrier. In one embodiment (see fig. 13B), elements (e.g., proximity sensors and shielding material) may be bonded to the compressible foam. The shielding material may shield the antenna from EMI generated by the components. At 2316, an antenna carrier including an antenna may be disposed in the housing, such as in a cavity associated with the RF antenna window. In 2320, the antenna may be aligned with the cover glass and then in 2322, the antenna may be engaged to the cover glass. When the cover glass is fixed in place, the foam may be compressed so that a force is applied by the antenna carrier that presses the antenna against the cover. In addition, the force exerted by the foam may enhance the seal between the antenna and the cover, such as by minimizing air gaps. Minimizing air gaps may limit variations in wireless performance between devices that may result from having air gaps that vary between devices. Large variations in wireless performance between devices may be undesirable.

Fig. 19 illustrates a particular embodiment of a portable computing device 3100. More particularly, fig. 19 illustrates a complete top view of the fully assembled portable computing device 3100. The portable computing device 3100 may process data, and more particularly media data, such as audio, video, images, and so forth. For example, the portable computing device 3100 may generally correspond to a device that may be implemented as a music player, a game player, a video player, a Personal Digital Assistant (PDA), a tablet computer, a camera, and/or others. In a handheld aspect, the portable computing device 3100 can be held in one hand by a user while being operated by the user's other hand (i.e., without the need for a reference surface such as a desktop). For example, the user may hold the portable computing device 3100 in one hand while operating the portable computing device 3100 with the other hand by, for example, operating a volume switch, a lock switch, or by providing input to a touch-sensitive surface (such as a display or a tablet).

The portable computing device 3100 may include a single piece housing 3102, which may be formed from any number of materials (e.g., plastic or metal) that may be machined, forged, cast, or otherwise processed into a desired shape. In those instances where the portable computing device 100 has a metal housing and contains RF-based functionality, it may be advantageous to provide at least a portion of the housing 3102 in the form of a radio (or RF) transparent material (e.g., ceramic or plastic) to allow transmission of RF signals therethrough. In either case, the housing 3102 may be configured with a cavity to at least partially enclose any suitable number of internal elements associated with the portable computing device 3100. For example, the housing 3102 may enclose and support various internal structural and electrical elements (including integrated circuit chips and other circuitry) to provide computing operations for the portable computing device 3100. The integrated circuit may take the form of a chip, chipset, or module, any of which may be surface mounted to a Printed Circuit Board (PCB) or other support structure. For example, a Main Logic Board (MLB) may have an integrated circuit mounted thereon, which may include at least a microprocessor, semiconductor (e.g., FLASH) memory, various support circuits, and the like.

Housing 3102 may include an opening 3104 for placement of internal components therein, and may be sized to accommodate a system or display assembly suitable for providing at least visual content to a user, e.g., via a display. In some embodiments, the display system may include touch sensitive capabilities that provide the user with the ability to provide tactile input to the portable computing device 3100 using touch input.

The display system may be formed of multiple layers. A separate transparent protective layer 3106 formed of polycarbonate or other suitable plastic or high-polished glass may be positioned over the display system. By using a high-polish glass, protective layer 3106 may take the form of cover glass 3106, which substantially fills opening 3104. Bezel bead 3108 may be used to form a seal between cover glass 3106 and housing 3102. Bezel molding 3108 may be formed from a rigid plastic material. In this manner, bezel strip 3108 can provide protection to the edges of cover glass 3106. The bezel layering 3108 can be injection molded plastic with a very thin cross section and can therefore be very difficult to operate, control, and measure. It may also be very difficult to consistently form the border strip 3108 to the same size because variations in temperature and humidity at the forming location may cause a large percentage increase or decrease in the size of the border strip 3108. Thus, the housing and bezel beads of different bins (bins) may be sorted and then matched so that the correct housing and bezel beads may be matched to minimize the gap between housing 3102 and bezel bead 3108 to about 0.05 millimeters.

In this embodiment, a track 3110 may be defined as the uppermost portion of housing 3102, which surrounds cover glass layer 3106. To maintain the desired aesthetic look and feel of the portable computing device 3100, it is desirable that any deviation between the housing 3102 and the cover glass 3106 be minimized by centering the racetrack 3110. A display panel (shown in fig. 28) located below cover glass 3106 may be used to display images using any suitable display technology, such as LCD, LED, OLED, electronic ink, e-ink, or the like.

The portable computing device 3100 may include a number of mechanical controls for controlling or modifying certain functions of the portable computing device 3100. For example, the power switch 3114 may be used to manually power on or off the portable computing device 3100. The slide switch 3116 may be used to mute any audio output provided by the portable computing device 3100, while the volume switch 3118 may be used to increase/decrease the volume of audio output by the portable computing device 3100. In the depicted embodiment, the slide switch 3116 may be a slidable switch and the volume switch 3118 may be a rocker switch. In other embodiments, the slide switch 3116 may be provided for other functions. It should be noted that each of the input mechanisms described above are typically disposed through openings in housing 3102 to enable coupling with internal components.

The portable computing device 3100 may include mechanisms for wireless communication, either as a transceiver-type device or simply a receiver (e.g., a radio). The portable computing device 3100 may include an antenna that may be disposed inside a radio-transparent portion of the housing 3102. In some embodiments, the antenna may be incorporated into bezel strip 3108 or cover glass 3106. In other embodiments, a portion of the housing 3102 may be replaced with a radio transparent material in the form of an antenna window 3140, which will be 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, etc. Any number of antennas may be used, which may use a single window or multiple windows depending on system requirements. In one embodiment, the system may include at least first and second antenna windows built into the housing.

Fig. 20 illustrates a top perspective view of the portable computing device 3100 in accordance with the described embodiments. As shown in fig. 20, the portable computing device 3100 may include one or more speakers 3120 for outputting audible sounds. The portable computing device 3100 may also include one or more connectors for transferring data and/or power from the portable computing device 3100 or to the portable computing device 3100. For example, the portable computing device 3100 may include multiple data ports, one configured for each of portrait and landscape modes. However, the presently described embodiment includes a data port 3122 that may be formed by a connector assembly 3124, the connector assembly 3124 being received within an opening formed along a first side of the housing 3102. In this manner, the portable computing device 3100 may utilize the data port 3122 with external devices when the portable computing device 3100 is mounted to a dock. It should be noted that in some cases, the portable computing device 3100 may include an orientation sensor or accelerometer that may sense the orientation or motion of the portable computing device 3100. The sensor may then provide an appropriate signal that will then cause the portable computing device 3100 to present the visual content in the appropriate orientation. Such sensors may be coupled to sensor board 3200, as described in more detail below.

The connector assembly 3124 may be any size deemed suitable, such as a 30-pin connector. In some cases, the connector assembly 3124 can function as both a data and power port, thus eliminating the need for separate power connectors. The connector assembly 3124 may vary widely. In one embodiment, the connector assembly 3124 may take the form of a peripheral bus connector, such as a USB or FIREWIRE connector. These connector types include both power and data functionality, allowing both power transfer and data communication between the portable computing device 3100 and the host device when the portable computing device 3100 is connected to the host device. In some cases, the host device may provide power to the media portable computing device 3100, which can be used to operate the portable computing device 3100 and/or to charge a battery included therein while operating.

FIG. 21 illustrates a bottom perspective view of a portable computing device in accordance with the described embodiments. Internal perspective views of a housing 3102 suitable for enclosing the operational elements of the portable computing device 3100 can be seen in fig. 22, 26, and 28. As shown in fig. 22, the housing 3102 is formed with an opening 3104 into which the internal components are placed 3104. A cavity in the center of housing 3102 provides space for battery cells 3304 and MLB 3312. Other components are typically disposed around the perimeter of battery cell 3304 and MLB 3312. Some elements may be located in a smaller groove formed in an edge portion or ledge 3156 of housing 3102. For example, RF antenna 3204 is located in RF antenna recess 3206, and camera 3134 is located in camera recess 3136. The magnets 3202 in cooperation with the cover may be located in slots 3168 along the edge of the housing 3102. Fig. 22 also shows openings 3142, 3144 in the housing 3102 for receiving the slide switch 3116 and volume switch 3118.

Corner brackets 3150 may be added to the single piece housing 3102 in each corner to stiffen and increase the rigidity of the housing 3102 in those areas. Openings or holes 3180 for buttons and switches, including a slide switch 3116 and a volume switch 3118, may also be provided in the housing 3102. Speaker holes or speaker grills 3170 may also be formed in the housing 3102. Speaker attachment members 3158 may also be provided on the ledge 3156 for attaching the speaker module 3320. In the depicted embodiment, a speaker attachment member 3158 is provided for attaching a substantially L-shaped speaker module 3320. Housing 3102 may also be formed with additional features 3172 for attaching or aligning components, such as MLB 3312.

The shape of the housing may be asymmetric in that the upper portion of the housing may be formed to have a shape that is completely different from the shape exhibited by the lower portion of the housing. For example, the upper portion of the housing may have a surface that meets the unique angle forming a well-defined edge, while the lower portion may be formed to have a substantially flat bottom surface. The transition region between the upper portion having the distinct edge and the substantially flat lower portion may take the form of an edge having a rounded spline shape that provides both a natural variation from the upper portion of the housing (i.e., the region of the distinct edge) and a smoother substantially flat surface presented by the lower portion of the housing. It should also be noted that in addition to providing a more aesthetically pleasing transition, the rounded spline shape of the edges in the transition region may provide a more comfortable feel when the user holds it in his hand, whether in use or simply on his hand. One advantage of using metal as the housing is that the metal can provide a good electrical ground for any internal components that require a good ground plane. For example, built-in RF antenna performance may be substantially improved when a good ground plane is provided. Also, a good ground plane may be used to help mitigate deleterious effects due to, for example, electromagnetic interference (EMI) and/or electrostatic discharge (ESD).

The housing 3102 may include a number of components for facilitating mounting of internal elements for use in components of the portable computing device 3100, as shown in fig. 22. These components are integral with the unitary body structure of the enclosure 3102 and need not be separately mounted to the enclosure 3102. Thus simplifying assembly of the portable computing device 3100. In the depicted embodiment, the one-piece housing 3102 may be formed from a single sheet or block of metal (e.g., aluminum) and formed into a suitable shape using, for example, core metal forming techniques well known to those skilled in the art.

For example, a groove 3206 may be formed in housing 3102, appropriately sized and positioned for an RF antenna. In the case where the groove 3206 is used to place an RF antenna, the groove 3206 may support an RF antenna support assembly formed of at least some radio transparent material. For example, the RF antenna support component may be foam that is pre-loaded into the groove 3206 before the RF antenna 3204 is placed in the groove 3206. The foam RF support assembly may bias the RF antenna 3204 toward the display assembly 3132 such that a consistent distance exists between the RF antenna 3204 and the display 3132 to enhance the performance of the RF antenna 3204. The RF antenna 3204 may be adhered to the display assembly 3132 using, for example, a PSA. By providing an RF antenna support assembly and RF antenna window 3140 formed of at least some radio transparent material, the RF antenna support assembly and RF antenna window 3140 may facilitate the unimpeded transmission and reception of RF energy in support of any number of wireless protocols (e.g., WiFi, bluetooth, etc.). It should be noted that the ability to provide unobstructed RF functionality is particularly important when housing 3102 is formed of radio frequency opaque materials (e.g., most metals).

The following discussion describes specific methods of minimizing the Z-height of the assembled components and maximizing the density of the components in housing 3102. In other words, the Z-stack associated with the internal components being mounted enables the components to be easily received by the cavities in housing 3102 without the need for a lengthy and time-consuming assembly process. The reduced Z-stacking and improved component density can be achieved in a number of ways, such as configuring the structure of the internal components to perform multiple functions.

For example, the portable computing device 3100 may include a battery assembly. The battery assembly may, in turn, include battery cell 3304, which may be attached directly inside the bottom wall of housing 3102. In one embodiment, Pressure Sensitive Adhesive (PSA) tape 3105 as shown in fig. 26 may be used to attach battery cells 3304 directly to housing 3102 without a conventional battery pack or frame. In the depicted embodiment, two PSA tapes 3105 are used to adhere each cell 3304. Attaching each battery cell 3304 directly to housing 3102 avoids the need for a separate battery support/protection structure (such as a battery compartment typically used in conventional battery packs). Such a battery compartment is typically a plastic casing that surrounds the battery cells. The plastic enclosure is separate from the computer or equipment housing. In the described embodiment, a protective chassis for the battery cell 3304 may be provided by the housing 3102 and the display 3132 mounted directly to the housing 3102. By eliminating separate battery compartments, the overall weight and z-stack height of the power module can be reduced over that required by conventional batteries.

In the depicted embodiment, all of the battery cells 3304 are directly welded to the same Battery Management Unit (BMU) 3306. In other embodiments, the individual battery cells 3304 may be electrically connected to each other by way of a flexible connector or wire. The flexible connector may in turn be soldered to BMU 3306. BMU 3306 may be used for some or all of the battery cells in a device.

A void (referred to as an expansion void) 3107 may be provided for accommodating expansion that is expected to occur during normal operation of the battery cell 3304. An expansion gap 3107 may be provided in the space between the PSA tape between the bottom wall of housing 3102 and the lower surface of cell 3304. An expansion void 3107 may also be provided in the space between the top surface of the battery cell 3304 above the battery cell 3304 and the bottom surface of the display assembly 3132. By providing expansion void 3107 under cell 3304, space between cell 3304 and housing 3102 that would otherwise be wasted can be utilized in a manner that is cost-effective to produce. According to one embodiment, all of the battery cells 3304 may be welded to the same BMU 3306.

As shown in fig. 23, there is generally no structure between the battery cells 3304 that are held in their desired positions on housing 3102 by adhesive. To utilize the space between the battery cells 3304, a connector cable 3308 may be placed between the two cells, as shown in fig. 23. In the illustrated embodiment, this particular connector cable 3308 connects MLB3312 and sensor board 200 to which the sensor may be coupled. The sensor may be designed to sense things that may make the portable computing device 3100 intelligent decisions. In essence, the sensors may provide information or cues that help anticipate future use of the portable computing device or the needs of the user so that the device 3100 may be configured accordingly. In most cases, the sensors are configured to sense one or more environmental attributes around the portable computing device 3100. Such environmental attributes may include, for example, temperature, ambient light, motion, vibration, pressure, touch, pressure, noise, direction, time, force, and/or the like.

Thus, the sensors may include antenna proximity sensors, compasses, accelerometers, gyroscopes, and hall effect sensors mounted on the sensor board 3200. The sensor board 3200 may extend from the region of the magnet 3202 all the way along the peripheral edge of the battery cell 3304 to a corner of the device 3100 proximate one of the RF antennas 3204, as shown in fig. 23. It should be noted that the compass should be placed on the sensor board 3200 as far away from the magnet 3202 as possible to prevent interference. The sensor board 3200 may also be connected to a camera 3134, an Ambient Light Sensor (ALS)3146 and a thermal sensor 3148, as well as a slide switch 3116 and a volume switch 3118. Connector cable 3308 provides a path to connect all components coupled to sensor board 3200 with MLB 3312. By placing cable connectors 3308 in an otherwise unused space between two battery cells 3304, the total footprint of the components in the cavity is minimized, while at the same time minimizing the Z-stack height by utilizing space in a more efficient manner. Furthermore, it is important to keep the accelerometers and gyroscopes as far away as possible from MLB3312 and its power traces to minimize crosstalk, so connector cables 3308 located between battery cells 3304 are an effective and neat way to connect the accelerometers and gyroscopes to MLB3312 while keeping them as far away as possible. Sensor board 3200 may be rigidly attached to housing 3102 by using a PSA having a foam layer on its top surface to bias sensor board 3200 down towards housing 3102.

The density of the elements can also be increased. For example, circuits that would otherwise be considered separate may be combined to share a single connector. For example, as discussed above, all of the components coupled to sensor board 3200 may be coupled to MLB3312 by a single connection, which in this case is connector cable 3312. In addition, the audio module may include both a microphone and associated circuitry, which may share a flexible connector with the audio circuitry used to generate the audio output. In this way, both the number of internal components and the total footprint can be substantially reduced without adversely affecting the overall functionality. In this way, the overall element density can be increased while at the same time reducing the number of interconnects used.

Fig. 23-30 illustrate operational elements of the portable computing device 3100. The operational elements are organized substantially in a single layer to minimize the Z-stack height of the portable computing device 3100. Thus, most of the internal elements of the portable computing device 3100 are substantially in a single plane. As described in more detail below, most of the components may be mounted directly to housing 3102. In this way, minimizing the Z-stack height, the portable computing device 3100 may have a thin profile at a relatively low cost, and be very compact, rugged, aesthetically pleasing, and ergonomic.

Fig. 23 illustrates an internal top view of the portable computing device 3100 showing a specific arrangement of various internal elements. In the illustrated embodiment, the internal components may include at least a battery assembly, which may include three individual battery cells 3304. Individual battery cells 3304 may be attached directly to housing 3102 by using an adhesive (e.g., PSA tape). Other types of adhesives or mounting methods may also be used to attach battery cell 3304 to housing 3102.

The internal components may also include a Main Logic Board (MLB)3312, which may include a number of operational circuits, such as a processor, graphics circuitry, (optional) RF circuitry, semiconductor memory (e.g., FLASH), etc. MLB3312 may receive power from battery cells 3304 by way of electrical connectors. As shown in fig. 23, battery cell 3304 and MLB3312 are located in the center of the cavity in housing 3102, while most other internal components are located in substantially the same plane around the periphery of the cavity. As described in more detail below, space is conserved by utilizing a thin connector (e.g., a flexible connector), and by fitting the connector into a space that would otherwise not be used. In this way, the total footprint and Z-stack height of the internal components can be minimized. Arranging certain elements at the periphery also serves to isolate certain elements from other elements to improve the performance of those elements by preventing, for example, cross-talk.

The internal components may also include a sound stage module 3320, which may include audio circuitry configured to provide audio signals to audio drivers 3322 and 3324, which may be located below the speaker grill 3120. In turn, audio drivers 3322 and 3324 may provide audible output to speaker 3120. Fig. 29 shows a more detailed view of the speaker module 3320 of the illustrated embodiment. It should be understood that audio drivers 3322 and 3324 are not visible in the view shown in fig. 29. Shock absorbing foam 3350 may be placed on the top and bottom of the speaker module 3320 at the end closest to the sensor on the sensor board 3200 to protect the sensor, especially the gyroscope, by damping vibrations from the speaker module 3320. The foam 3350 on the bottom of the speaker module 3320 may also be used to create an acoustic seal to the enclosure 3102 so all sound from the speaker module 3320 is directed outside of and out of the portable computing device 100.

The portable computing device 3100 may also include multiple antennas for both transmission and reception of RF energy. For example, at least one RF antenna 3204 may be incorporated in a groove 3206 in housing 3102. In the illustrated embodiment, there are two RF antennas 3204, one disposed in each groove 3206. A radio transparent window 3140 may be provided in the housing 3102 in the area of the RF antenna 3204 to enable better overall reception/transmission. Another antenna 3208 for supporting a wireless WiFi protocol may be provided near a peripheral edge of the housing for better antenna performance. Connector cable 3210 may couple WiFi antenna 3208 with MLB 3312.

In some embodiments, the portable computing device 3100 may support a plurality of different wireless standards. For example, in those instances in which the portable computing device 3100 supports a particular wireless standard (e.g., the 3G standard), the portable computing device 3100 may include wireless circuitry that is appropriate for the particular wireless standard. For example, if the portable computing device 100 is 3G compliant, the MLB3312 may include 3G wireless circuitry coupled with an RF antenna 3204 whose position and size are appropriately determined. Alternatively, in the illustrated embodiment, the RF antenna may be coupled with a radio board 3314. In the illustrated embodiment, the radio board 3314 is coupled to the MLB3312 via a flexible connector 3316, as shown in fig. 23. It should be noted that as discussed above, a portion of housing 3102 is typically replaced with a radio transparent window 3140 that cooperates with RF antenna 3204.

In the illustrated embodiment, the display bus 3344 may connect the display driver circuitry to the MLB3312 via a display connector 3346, as shown in FIG. 23. In the described embodiment, display bus 3344 may take the form of a Low Voltage Differential Signaling (LVDS) bus. In the illustrated embodiment, the display bus 3344 may be configured to connect the display driver circuitry with the MLB3312 while maintaining a thin profile because the display bus 3344 is configured to be flat regardless of the number of wires required for such an LVDS bus. In one embodiment, display bus 3344 includes 30 wires that may be bundled in certain sections and then fanned out into a single layer or two layers in other sections.

Fig. 25 shows a cross-section 3600 of fig. 24 along line AA, intersecting battery cells 3304 and MLB 3312. Fig. 26 shows a cross section 3700 of the battery cell 3304 taken transversely along line BB of fig. 27. In particular, sections 3600 and 3700 illustrate the compactness and reduced Z-stack height of the assembled internal elements. As shown in fig. 26 and 27, the components (including the battery cell 3304 and the MLB 3312) located under the display 3132 are substantially in the same plane. As shown, these elements are mounted to a substantially flat bottom surface of housing 3102. To avoid unnecessary interference from RF transmissions from RF antenna 3204, antenna window 3140 may be formed from a radio transparent material (e.g., plastic, glass, ceramic, etc.). The display module circuit 3506 may be connected to the LVDS bus 3344 by means of the connector 3346 and used to drive the display panel 3132. Fig. 28 illustrates an exploded perspective view of the main internal elements of the portable computing device 3100. Fig. 28 also illustrates an internal perspective view of a housing 3102 suitable for enclosing the operational elements of the portable computing device 3100 described herein.

The display assembly 3132 may be placed and secured in the cavity by using various mechanisms. In one embodiment, the display system 3132 may have alignment holes that may align with alignment holes on the housing 3102 to precisely align the display 3132. Temporary fasteners may be used to align the alignment holes in the display 3132 with the alignment holes in the ledge 3156 of the housing 3102 to better center the display. When the temporary mount is in place, the operator can screw the display 3132 to the housing 3102. The display may be placed flush with adjacent portions of the housing 3102. In this way, the display may present visual content, which may include videos, still images, and icons, such as a Graphical User Interface (GUI), which may provide information (e.g., text, objects, graphics) to a user and receive input provided by the user. In some cases, the displayed icon 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 the GUI from one location to a more convenient location. The display may also provide the user with haptic feedback provided by a plurality of haptic actuators, typically, but not necessarily, arranged in an array of haptic actuators incorporated into the display. In this way, the haptic actuator may provide haptic feedback to the user.

In certain embodiments, a display mask (not shown) may be applied to or incorporated within or below the cover glass 3106. The display mask can be used to emphasize unmasked portions of the display for presenting visual content. The display mask may be used to set a less obvious home button 3112 for providing specific inputs, such as changing the display mode of the portable computing device 3100, for example. The display mask may be rendered less conspicuous by, for example, being closer in hue or color to the home button 3112. For example, if the home button 3112 is formed of a material that is slightly darker (e.g., gray or black) than the color of the cover glass 3106, the visual impact of the home button 3112 can be reduced using a display mask of a similar color when compared to the unmasked portion of the cover glass 3106. In this way, the visual impact of the home button 3112 can be reduced by integrating it into the overall appearance of the display mask. In addition, the display mask may provide a natural mechanism for directing the viewer's attention to unmasked areas of the display for presenting visual content. A PSA may also be applied in the display mask area on the back of cover glass 3106 to provide support and also act as a safety glass in the event that cover glass 3106 shatters.

Fig. 23 also shows one embodiment of a SIM card release mechanism 31100 according to the described embodiment. The SIM card release mechanism 31100 may include a tray 31102 (fig. 28) adapted to hold a SIM card when placed thereon. Embedded magnets 3202 may also be provided in the housing 3102 at the magnet slots 3168 at the edge of the housing 3102. The magnet 3202 may be used in conjunction with a segmented cover assembly that may be used for what is referred to as a peek mode of operation of the portable computing device 3100. When a segment of the cover assembly is raised from the glass cover 3106, the sensor in the portable computing device 3100 may detect the segment of the cover assembly, and only the segment is raised from the glass cover 3106. Once detected, the portable computing device 3100 may trigger only the exposed portion of the display 3132. For example, the portable computing device 3100 may apply a hall effect sensor to detect that the segment has been lifted from the glass cover 3106. In the illustrated embodiment, hall effect sensors may be mounted on the sensor board 3200. Fig. 22 shows an attachment point 3166 for a hall effect sensor. Other sensors (e.g., optical sensors) may then detect whether only the segment is elevated, or whether other segments are elevated. Such a sensor is located adjacent to and coupled to sensor board 3200 adjacent to magnet 3202.

The portable computing device 3100 may include one or more button assemblies by which a user of the portable computing device 3100 may trigger various functions. The button assembly may be mounted through a face of the cover glass 3106 in the portable computer device 3100 or through a front, side, or back portion of the single piece housing 3102 of the portable computer device 3100. The button assembly may be designed to provide a desired tactile feedback to a user when a function of the button assembly is triggered. Furthermore, in conjunction with the design of the external surface and internal connection points of the portable computing device 3100, the button assembly can be designed to be positioned approximately flush with the external surface in a neutral "not pressed" state, even with an internal circuit board located at a distance from the top of the button assembly.

FIG. 30 illustrates a first cross-sectional perspective view 3800 of the home button assembly 3802 mounted through a cover glass 3106 of the portable computing device 3100, in accordance with the described embodiments. The home button assembly 3802 may include an outer flat or curved button body 3112 that is approximately flush with the outer surface of the cover glass 3106. The flange 3804 may be mounted to (or integrally formed with) the underside of the outer button 3112 and extend below the underside of the cover glass 3106. The center post 3806 may be mounted to a lower side of the outer button body 3112 above the tactile switch unit 3808 (or integrally formed therewith), and the tactile switch unit 3808 may be mounted to the bracket 3820. The bracket 3820 may be formed of metal (e.g., stainless steel) and may be adhered to the cover glass 3106 by an adhesive 3826 (e.g., PSA). In a neutral "not depressed" state, the central post 3806 may be a distance from the tactile switch unit 3808. When the outer button body 3112 is pressed, the center post 3806 may be in contact with the tactile switch unit 3808 in such a manner as to cause a contact circuit in the tactile switch unit 3808 to be closed. The use of the tactile switch unit 3808 may enable a user of the portable computing device 3100 to experience different "feelings" when pressing different positions on the surface of the external button body 3112, because the external button body 3112 can be rotated about the top of the tactile switch unit 3808 as a pivot.

Internal elements of the portable computing device 3100 may include a flexible circuit or wire 3818 through which signals may be conducted as a result of pressing the external button 3802. The wire 3818 may be located at a distance from the contact point of the tactile switch unit 3808. This distance may prevent the tactile switch unit 3808 from being directly mounted on the electric wire 3818 because the moving distance of the center post 3806 of the outer button body 3112 may be too short to reach the tactile switch unit 3808 when pressed to trigger a function. The wire 3818 may further include an element that prevents the tactile switch unit 3808 from being directly mounted to the wire 3818 in an area directly under the external button body 3112. Instead, a connection between the wire 3818 and the tactile switch unit 3808 may be provided.

As shown in fig. 30, the tactile switch unit 3808 may be mounted to a printed circuit board 3810 in the middle. In certain implementations, the intermediate printed circuit board 3810 may be connected to a flexible circuit or wire 3818 by a flexible cable; however, such connections can complicate the assembly process. In some embodiments, the flexible cable connection may not allow for simple, machine automated assembly, but rather requires manual assembly by a technician. The representative embodiment shown in fig. 30 enables connection to the electrical wires 3818 from the intermediate printed circuit board 3810 by a pair of conductive posts 3814/3816 and a pair of conductive plates 3812/3813, thereby avoiding manual assembly. For example, the first conductive pillars 3814 may be connected to a DC power level supplied through the electric wires 3818, and the second conductive pillars 3816 may be connected to a GND level in the electric wires 3818. The conductive posts 3814 and 3816 may be connected to separate conductive plates 3812 and 3813, respectively, mounted on the underside of the intermediate printed circuit board 3810. Stiffening members may be placed under the conductive posts 3814 and 3816 to increase stiffness.

Pressing the external button body 3112 closes a circuit in the tactile switch unit 3808, which connects the first conductive post 3814 to the second conductive post 3816, thereby allowing a current to flow, which may directly or indirectly trigger a function of the portable computing device 3100. In addition to providing conductive paths, the conductive posts 3814 and 3816 may be sized and positioned between the intermediate printed circuit board 3810 and the wires 3818 to "tune" the tactile feel of the button assembly 3802 for a user of the portable computing device 3100. For example, the conductive posts 3814 and 3816 may be located closer to each other or farther apart, and the thickness of the intermediate printed circuit board 3810 may be varied to increase or decrease the flexibility that may be created when the outer button 3802 is pressed to contact the tactile switch unit 3808.

As shown in fig. 30, an intermediate circuit board 3810 may be mounted to the tactile switch unit 3808. Fig. 31 shows a simplified top view of the home button assembly with a flange 3804 that extends a small portion from under the outer button body 3112. The top of the outer button body 3112 may include orientation markings 3822 that may assist the user in locating the outer button body 3112 and guide the user in pressing in place on the outer button body. The directional indicia 3822 may take various forms, including tactile prominence or compass point (e.g., north (N) and south (S)) indicia. During operation of the portable computing device 3100, a user may press at a location that is not centered on the surface of the external button body 3112. A curved or reversed loop 3824 may be provided around the orientation mark 3822.

The button assembly may also be mounted by enclosing a portion of the single piece housing 3102 of the portable computing device 3100. Because this single piece housing 3102 may be relatively thin to reduce the weight of the portable computing device 3100, the opening in the housing 3102 may affect the structural integrity of the portion of the housing 3102 near the opening. For relatively larger openings, structural support portions may be included inside housing 3102 to increase rigidity; however, the button assembly may still require access through the structural support portion. It may be desirable to minimize the size of the opening through the structural support portion to maintain the desired strength of the structural support when using a relatively large outer button that may use a relatively large opening in the housing 3102.

In some embodiments, the portable computing device 3100 may include a camera module 3134 configured to provide still and video images. The arrangement may be widely varied and may include one or more locations including, for example, the front and back of the device, i.e., one through the back housing and the other through the display window. As shown in fig. 21, a back camera window 3138 may pass through the housing 3102. A front camera window 3139 (fig. 33) may also be provided for a camera through the front of the display window. Fig. 23 shows a camera window at camera module 3134 through a display window in front of device 3100.

Camera module 3134 may be aligned with display 3132 by using alignment pins 3130 provided by a bottom surface of display 3132, as shown in fig. 23. These alignment pins 3130 align with holes 3152 and slots 3154 in the top surface of camera module 3134 shown in fig. 23. These alignment pins 3130 and corresponding holes 3152 and slots 3154 in the camera module help align the camera 3134 with the display 3132 in the x and y directions. As shown in fig. 34, a flexible connector 3160 extending below the camera module 3134 and wrapping around from the side to the top of the camera module 3134 may couple all of the camera module 3134, ALS 3146 and thermal sensor 3148 to a sensor board 3200, which in turn is connected to the MLB 3200.

An Ambient Light Sensor (ALS)3146 and a thermal sensor 3148 may also be provided on an area of the camera module 3134. The ALS 3146 may sense when the device 3100 is in a dark environment or when the device 3100 is in a bright environment. The ambient light may include light surrounding the portable computing device 3100, which is generated by sunlight, incandescent light, fluorescent light, and so forth. If the portable computing device 3100 is in a dark environment, the display 3132 of the portable computing device 3100 may be powered down to make the brightness lower and save battery power. Conversely, if the portable computing device 3100 is in a bright environment, the display 3132 may increase power to increase brightness. For example, the display 3132 may be dimmed when the ALS 3146 senses that the ambient light level has decreased by an amount or reached a predetermined or specified level of darkness, while the display 3132 may be brightened when the ALS 3146 senses that the ambient light level has increased by an amount or reached a predetermined or specified level of brightness.

In some cases, multiple ambient light sensors may be used. This may help to produce a more accurate reading of the ambient light, for example by averaging. This may also help determine whether the portable computing device 3100 is really in a dark environment, rather than when light is blocked from reaching the ALS 3146 (e.g., if one sensor is blocked, the other sensors still sense the surrounding environment).

Thermal sensors 3148 may provide temperature data for device 3100 to prevent overheating. The thermal sensor 3148 may distinguish between external heat and internal heat. For example, the thermal sensor 3148 may distinguish heat received by the device 3100 from sunlight from heat generated by internal elements of the device 3100.

The camera module 3134 with ALS 3146 and thermal sensor 3148 may be mounted to the housing by first pre-loading the foam support into the recess 3136 before the camera module 3134 is placed in the recess 3136. The foam support may bias camera module 3134 towards display assembly 3132, while camera module 3134 adheres to the display assembly using, for example, a PSA. Because ALS 3146 and thermal sensor 3148 are proximate to cover glass 3106, no light pipes or guides are needed. The sensor may be located near the display 3132, utilizing a window and cover glass 3106 that typically covers and protects the display 3132. In this way, the sensor may also be hidden from view. A light diffuser may also be provided.

Fig. 35 shows a flow chart describing a process 31500 for assembling internal elements of a portable computing device according to the described embodiments. Process 31500 begins at 31502 with receiving a housing suitable for enclosing and supporting internal elements of a portable computing device. In the described embodiments, the housing may be formed to include a cavity having a substantially flat bottom surface. The housing may also be formed with smaller recesses along the peripheral edge portion for receiving components. The components may include, for example, a battery assembly, a main printed circuit board, a main logic board, buttons, a speaker module, and the like. The housing may be formed using any well known machining operation. Once the housing has been received 31504, the element may be inserted 31506 into the cavity and directly contacted 31508 with the inner surface of the housing. Once it is placed directly over the substantially flat interior surface of the housing, the element may be attached to the housing at 31510 using any well-known attachment process (e.g., adhesive, bonding, epoxy, welding, etc.).

Portable electronic devices manufactured in large numbers may include Computer Numerically Controlled (CNC) machined metal alloy components having surfaces of various geometries. Representative portable electronic devices may include portable media devices, portable communication devices, and portable computing devices, such as those manufactured by apple Inc. of cupertino, californiaAndboth the tactile and visual appearance of portable electronic devices may increase consumer demand for the portable electronic devices. Metal alloys can provide lightweight materials that exhibit desirable properties (e.g., strength and thermal conductivity) that are well suited for use as housings for portable electronic devices. Representative metal alloys can include aluminum alloys. Both the tactile and visual appearance of portable electronic devices may increase consumer demand for such devices. A decorative outer layer machined from a metal alloy may be cut to a desired shape and polished to a desired reflective and/or matte appearance. In some embodiments, a continuous smooth shape with a visually uniform smooth appearance may be desired.

High volume manufacturing may also require minimal processing time. Machining the aluminum blank with a single cutting tool to form the exterior surface of the housing of the portable electronic device may reduce the required processing time. Machining using a single continuous optimized path results in a "rough" cutting surface that can require minimal sanding and polishing to produce a visually smooth finished product without visually discernable interruptions between regions of different cross-section. The curved region may smoothly transition to the flat region, including along the corner regions, without any visual change in surface appearance.

Fig. 36 shows a cross section of a representative embodiment of a housing 4100 of a portable electronic device. The cross section shows a shape for the surface of housing 4100, which may include four different regions, including a first flat top edge region 4102, which may be straight in cross section, adjacent to an opening in the top of housing 4100 where elements of the portable electronic device may be placed. This flat top edge region 4102 may face a user of the portable electronic device when viewed directly from a display mounted in the portable electronic device. The flat top region 4102 may be shaped with a single continuous cut by a machining tool and polished to the appearance of a highly reflective surface. This flat top region 4102 may also be referred to as a "runway" edge. The cross-section of housing 4100 may also include two curved regions connected together, an arc region 4104 that may transition from the flat top edge region 4102 to a spline-shaped region 4106. The arc region 4104 may have a relatively higher curvature than the spline region 4106. The cross-section of housing 4100 may also include a flat bottom region 4108, which may smoothly transition from spline region 4106. A single cutting tool having multiple cutting surfaces may be used to shape the outer surface of housing 4100 to have the cross-section shown in fig. 1 by using a single continuous cutting path as described herein.

Fig. 37 shows a cross-section of a representative cutting tool 4200 having three distinct portions, each of which may be shaped to provide a cutting surface to machine one or more regions of a housing 4100 of a portable electronic device as shown in fig. 36. The cutting tool 4200 may be mounted in a CNC machine, rotated at a constant speed and positioned in different directions in a three-dimensional coordinate system to shape the metal alloy blank into a desired exterior surface shape. In particular, CNC machines may allow movement in the "z" direction to provide undershoot (negative "z") and ascent (positive "z"). The CNC machine may also allow movement in the "x-y" direction in a predetermined continuous path. The flat top rim portion 4202 of the cutting tool 4200 may be used to shape the flat top rim region 4102 of the housing 4100. The curved portion 4204 of the cutting tool 4200 may be used to shape the curved region 4104 and spline region 4106, while the flat base 4206 of the cutting tool 4200 may be used to shape the flat base region 4108 of the housing 4100. The curved portion 4204 of the cutting tool 4200 may be convex, such as may be a curved region of the housing 4100 shaped by the curved portion 4204 of the cutting tool 4200. Each adjacent region of the cutting tool 4200 may be used in succession as the cutting tool 4200 is moved along a continuous predetermined path. Careful changing of the "z" direction of the path may minimize sharp transitions between regions along the surface of the housing 4100 when changing between different portions of the cutting tool 4200 being used. The "z" direction can be orthogonal to the bottom surface of housing 4100, while the "x-y" direction can be along the edges and bottom surface of housing 4100.

Fig. 38A-D illustrate several locations for the cutting tool 4200 to shape different regions of the housing 4100 with different surfaces of the cutting tool 4200. As shown in drawing 4300 in fig. 38A, the flat top rim portion 4202 closest to the neck of the cutting tool 4200 may be provided to shape the flat top rim region 4102 of the housing 4100. The flat top edge region 4102 may be formed along a continuous path. After shaping the flat top edge region 4102, the cutting tool 4200 can transition to shaping the curved region of the housing 4100. As shown in diagram 4310 in fig. 38B, the upper portion of the curved portion 4204 of the cutting tool 4200 proximate to the flat top rim region 4202 may be used to form the curved region 4104 of the housing 4100. As shown in diagram 4320 in fig. 38C, the lower portion of the curved portion 4204 of the cutting tool 4200 may be used to shape the spline region 4106 of the housing 4100. As the CNC machine moves the cutting tool 4200 along the outer surface of the housing 4100, the curved portion 4204 of the cutting tool 4200 may be continuously moved in a direction relative to the housing 4100. As the CNC machine lifts the cutting tool 4200 to raise in the "z" direction, different portions of the curved portion 4204 of the cutting tool 4200 can contact and shape different regions of the housing 4100. Although not shown in the figures, the CNC machine may also tilt the cutting tool at different angles when cutting the surface of the housing 4100. As shown in diagram 4330 in fig. 38D, the flat bottom 4206 of the cutting tool 4200 can be used to form the flat bottom region 4108 of the housing 4100. The CNC machine may move the cutting tool 4200 in a continuous helical path to form a flat top region 4102, an arc region 4104, and spline regions 4106. The elevation in the "z" direction can be varied to ensure a uniform surface of the shaped housing 4100, with no visible joints or transitions after sanding and polishing the rough cut surface of the finished housing 4100.

The path of the cutting tool 4200 may be selected to provide a transition between different regions of the housing 4100 without abrupt changes in the frictional forces of contact between the cutting tool 4200 and the housing 4100. By ensuring a constant contact force and a uniform smoothly varying frictional load between the cutting tool 4200 and the housing 4100 during the transition between regions, the surface of the housing 4100 can be shaped without irregular cuts, such as gouges, notches, or surface distortions, that can damage the appearance of the final surface of the housing 4100. The continuous helical path for the cutting tool 4200 may maintain a smooth transition between different regions. The frictional load experienced by the cutting tool 4200 may vary with the amount of surface area of contact between the cutting tool 4200 and the housing 4100. Critical areas of the surface of housing 4100 that may be of particular interest to determine the cutting tool path include transition areas between the different shapes of the cross-section of the surface of housing 4100. Narrowing the spacing between successive loops of the continuous helical path used by the cutting tool 4200 may minimize abrupt changes in frictional loads, thereby ensuring a uniform cutting surface of the housing 4100. The transition regions may include a transition from the flat top edge region 4102 to the arc region 4104, a transition from the arc region 4104 to the spline region 4106, and a transition from the spline region 4106 to the flat bottom region 4108. Fig. 39 shows a drawing 4400 of a transition area 4404 between a spline region 4106 and a flat sole region 4108 for a cutting tool path 4402, illustrating movement of the center of a cutting tool 4200. The cross-sectional area of the housing 4100 surface that may include high curvature (e.g., high curvature region 4406 in arcuate region 4104) may also benefit from narrowing the spacing between successive loops of successive paths of the cutting tool 4200.

Fig. 40 shows a diagram 4500 with a tool path 4402, the tool path 4402 having a variable pitch in the "z" direction, which can be used for a continuous loop of cutting tools 4200 along a continuous helical path. Because the cutting tool 4200 forms the housing 4100 from a solid metal alloy block (e.g., aluminum billet), the tool path center 4502 may generally follow the shape of the surface of the housing 4100. As the cutting tool 4200 moves along the continuous helical path, the cutting tool 4200 may follow the continuous helical path around the housing 4100, slowly increasing the "z" height. Fig. 40 shows how the "z" height 4502 of the center of the cutting tool 4200 can vary for a continuous loop about a continuous helical path. When transitioning from the flat top edge region 4102 to the arcuate region 4104, the tool path 4402 can step in the "z" direction narrowly from the detail distance 4504. After such a transition, the tool path 4402 may be stepped wider in the "z" direction to speed up the machining of the housing 4100. The narrower spacing of the continuous loop of the cutting tool 4200 may minimize and avoid abrupt changes in friction between the surface of the housing 4100 and the cutting tool 4200.

In addition to the fine spacing in the transition region, CNC machining of the high curvature region 4406 through the arcuate region 4104 can take advantage of the "z" spacing of the detail pitch 4504 between successive loops of the continuous helical path. Spacing the loops close to each other avoids sharp transitions of frictional contact and provides a smooth, uniform cut in the arcuate region 4104. Similar to the fine spacing in the transition between the flat top edge region 4102 to the arc region 4104, in the transition region 404 from spline region 4106 to flat bottom region 4108, the cutting tool path 4402 may also be spaced at a fine pitch 4504 in the "z" direction. The surface area of the cutting tool 4200 in contact with the surface of the housing 4100 may increase substantially from the spline region 4106 to the flat bottom region 4108, and by spacing the loops closer to each other, the transition from minimum contact to wider contact may be made smooth to avoid gouging the housing 4100 during machining. The close spacing of the paths in the transition region 4404 may also eliminate visible transitions between the curved surface of the spline region 4106 and the plane of the flat bottom region 4108. After cutting, sanding, and polishing, the housing 4100 of the mobile device can have a uniform smooth appearance without noticeable differences between the curved edge surface and the flat bottom surface and without visible joints. When the flat bottom 4206 of the cutting tool 4200 is fully within the flat bottom region 4108 of the housing 4100, the continuous path taken by the cutting tool 4200 may change from a helical path to a saw-tooth path, i.e., a path having alternating straight paths across the flat bottom region 4108. The saw-tooth path may minimize warpage that may occur during processing due to temperature changes of the metal alloy on the surface of housing 4100. By careful placement of the tool path 4502 with fine pitch spacing along selected regions, the surface of the sanded and polished housing 4100 can have a visually continuous surface without edges or corners when viewed from the back.

Fig. 41 shows a pattern 4600 of a continuous loop of cutting tool 4200 along a portion of a continuous helical path of the surface of housing 4100, matching the pitch of the spacing to different regions of housing 4100. In region a 4616 of housing 4100, which may include flat top edge region 4102 and arcuate region 4104, adjacent loops of a continuous helical path may be spaced at a fine pitch 4602. This detail distance 4602 can ensure a smooth transition between the flat top edge region 4102 and the curved region 4104, as well as a smooth transition in the high curvature region 4406 of the curved region 4104. In region B4614 of housing 4100, which may be fully contained within spline region 4106, the spacing of the successive loops of the continuous helical path may utilize intermediate pitch 4604. The curvature of spline region 4106 may be less than the curvature in arc region 4104 and the curvature may also change more slowly in spline region 4106. The wider spacing of the continuous loop of the continuous helical path in zone B4614 may increase the processing speed of the housing 4100 without utilizing the narrow spacing of the continuous loop as employed in zone a 4616.

Because spline region 4106 is connected to flat bottom region 4108, cutting tool 4200 can transition from using curved portion 4204 to using flat bottom 4206. The amount of contact between the cutting tool 4200 and the surface of the housing 4100 may be substantially increased in the transition from the spline region 4106 into region C4612 of the flat bottom region 4108. The spacing between successive loops of the continuous helical path may be spaced with a fine pitch 4606 in region C4612 to slowly increase contact and avoid abrupt changes in the frictional forces experienced by the cutting tool 4200 when shaping the surface of the housing 4100 in region C4612. In region D4610 of flat bottom region 4108, the spacing between adjacent paths may gradually increase from the fine pitch employed in region C4612 to a wider pitch suitable for flat bottom region 4108. After reaching approximately one-quarter of the distance in the flat foot region 4108, the CNC machine may perform a large radius turn to transition from a continuous helical differential path for the curved edge region 4104/4106 of the housing 4100 to a continuous zig-zag path for the foot region 4108 of the housing 4100. This large radius turn may avoid sharp turn transitions that may affect the shaped housing 4100 surface. As shown in bottom view diagram 4700 in fig. 42, the continuous path may include a spiral path 4702 for curved edge region 104/106 and a zigzag path 4704 for the center of flat bottom region 4108. The spacing between adjacent ones of the zigzag paths 4704 may be wider than the spacing of adjacent loops of the spiral path 4702.

In one embodiment, the rotational and translational speeds of the cutting tool 4200 along the continuous path may be fixed. In certain embodiments, one or more characteristics of the cutting tool 4200 may be selected (fixed or variable along the cutting path) from: the characteristics may include, but may not be limited to, (1) feed speed (translation speed in one or more of the x-axis, y-axis, and/or z-axis directions), (2) axis speed (rotational speed), (3) pitch (spacing between adjacent cutting paths), (4) shape and size of the cutting tool 4200, e.g., diameter, (5) cutting material of the cutting tool 4200, and (6) rake angle of the cutting tool 4200 (angular orientation of the cutting tool 4200 relative to the surface of the housing 4100). The characteristics of the cutting tool 4200 may be selected to affect the final characteristics and machining time of the machined cutting surface of the housing 4100. The rotational and translational speeds may be selected to minimize machining time while ensuring the quality of the surface cut by the machining tool, which may result in a preferred finished surface. Fine control of the change in pitch between the loops of the continuous helical path may be used in regions of higher curvature, regions of higher rate of change of curvature and/or transition regions between regions of surfaces having different curvatures. Coarser control of the pitch between adjacent loops may be used in flat regions, low curvature regions, and regions with lower rates of curvature change. Moderate control may be used in regions of moderate curvature, while the pitch may vary continuously and smoothly between narrow fine pitch regions and wide coarse pitch regions. Although the use of fine control of pitch in a continuous path may provide a final surface with a desired uniformity, the processing time may be longer. Instead, where it is desired to ensure a smooth transition between regions having different cross-sectional shapes, the pitch may be controlled to finely step.

In one example, a single cutting tool 4200 may be used to shape the entire outer surface of metal alloy housing 4100, rather than multiple separate tools to shape the flat and curved regions. The single cutting tool 4200 may smoothly transition between different portions on the cutting tool 4200 to shape different regions of the metal alloy housing 4100 while maintaining continuous contact with the surface of the housing 4100. Multiple cutting tools may require additional time for their installation and removal on a CNC machine. Furthermore, different cutting tools may create a surface height mismatch across the shaped housing 4100 with undesirable step transitions that may be difficult to remove during final completion of the housing 4100 surface. With a single cutting tool 4200 having a single, continuous path as described herein, the formed housing 4100 may have a more uniform and seamless appearance when sanded and polished into a final exterior finish.

Fig. 43 illustrates a representative method of processing the edge and bottom surfaces of a metal alloy housing 4100 of a portable electronic device. The method may include grinding the edge surface of the metal alloy housing 4100 by contacting the rotating cutting tool 4200 to the edge surface along a first predetermined continuous helical path. The vertical height of the cutting tool 4200 may be adjusted using a CNC machine. The continuous loop of the helical path of the cutting tool 4200 may be spaced differently along different regions of the surface of the metal alloy housing 4100. The pitch of vertical movement that may affect the pitch between adjacent ones of the continuous helical paths may be adjusted based on the curvature of metal alloy housing 4100 resulting from the shaping of cutting tool 4200. The high curvature regions may have closely spaced adjacent paths, as may the transition region between the curved region and the flat region. The method may further include grinding the bottom surface of metal alloy housing 4100 by contacting rotating cutting tool 4200 to the bottom surface of metal alloy housing 4100 along a second predetermined path having an alternating straight path (i.e., a continuous saw tooth path). The spacing between adjacent ones of the paths along the bottom surface may be further apart than the spacing between adjacent ones of the helical paths along the edge surface of metal alloy housing 4100.

The various aspects, embodiments, implementations or features of the described embodiments may be used alone or in any combination. The various aspects of the described embodiments may be implemented in software, hardware, or a combination of hardware and software. The described embodiments may also be embodied as computer readable code on a computer readable medium for controlling a manufacturing operation or computer readable code on a computer readable medium for controlling a manufacturing line used to manufacture a thermoformed part. 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.

Fig. 44A shows a top view 5100 of a related art mobile device 5102 having a sliding tray 5104 that may be ejected from the mobile device 5102 after an ejection tool 5106 is inserted. The pop-up tool 5106 may be inserted in a direction perpendicular to an axis of an edge surface of the mobile device 5102, and the sliding tray 5104 may be at least partially popped from the mobile device 5102 in a direction of an axis substantially parallel to the pop-up tool insertion axis. The axis may be parallel to the flat top surface and/or the flat bottom surface of the mobile device 5102. The top and bottom surfaces may be perpendicular to the edge surfaces of the mobile device 5102.

Fig. 44B shows a front view 5110 of the mobile device 5102. This frontal view 5110 shows an ejection opening 5108 in the surface of the sliding tray 5104 through which an ejection tool 5106 may be inserted. The ejection opening may be circular to minimize its area. The length of the sliding tray 5104 may be greater than the height of the mobile device 5102, thus requiring the sliding tray to be oriented parallel to the surface of the mobile device so that the sliding tray may be completely enclosed within the mobile device when inserted.

Fig. 44C further illustrates a perspective view 5120 of the mobile device 5102 illustrated in fig. 44A and 44B. The edge surface of the mobile device 5102 may be perpendicular to the top surface, while the sliding tray 5104 may be inserted or removed in a direction perpendicular to the edge surface. Similarly, pop-up tool 5106 can be inserted through pop-up opening 5108 along an axis perpendicular to the edge surface. The insertion axis may be parallel to the ejection axis.

Fig. 45A shows a top view 5200 of the mobile device 5202 with a sliding tray 5204 that can be ejected from the mobile device 5202 after insertion of an ejection tool 5206. The pop-up tool can be inserted in a direction perpendicular to the axis of the edge surface of the mobile device 5102, and the sliding tray 5104 can be at least partially popped from the mobile device 5102 in a direction substantially parallel to the axis of the flat top surface and/or the flat bottom surface of the mobile device 5202. The edge surface may not be perpendicular to the flat top surface or the flat bottom surface of the mobile device 5202.

Fig. 45B shows a front view 5210 of the mobile device 5202, including an ejection opening 5208 in the housing of the mobile device 5202 adjacent to the sliding tray 5204. The pop-up opening 5208 is separable from the sliding tray 5204 in the mobile device 5202 to accommodate different shaft orientations than those used in the prior art mobile device 5102 shown in fig. 44A-C.

Fig. 45C shows a perspective view 5220 of the mobile device 5202 including an edge surface that is not perpendicular to the flat top or bottom surface of the mobile device. Pop-up opening 5208 may be oriented such that pop-up tool 5206 may be inserted along an axis orthogonal to an edge surface of the mobile device. The axis of insertion of ejection tool 5206 may form an angle 5212 with the axis parallel to the direction in which sliding tray 5204 may be ejected from mobile device 5202. If the axis of the ejection tool is oriented parallel to the axis of movement of the sliding tray 5204, the ejection opening in the angled edge surface of the moving device 5202 will be larger than the ejection opening 5208 shown in fig. 45C. The circular pop-up opening 5208 may be smaller than an oval pop-up opening (not shown) to minimize the pop-up opening through the housing of the mobile device 5202 to provide an aesthetically pleasing edge surface with minimal discontinuities.

Although fig. 45C shows an angled edge surface for the mobile device 5202 housing, curved edge surfaces can also be accommodated as shown in the perspective view 5230 of the mobile device 5222 in fig. 45D. The sliding tray 5214 in the mobile device 5222 can have a curved edge surface along its front face that can be coupled to the curved edge surface of the mobile device 5222 to provide a smooth uninterrupted edge surface for the mobile device 5222. The sliding tray 5214 can pop up along an axis parallel to the top surface of the mobile device 5222, while the center of the pop-up opening 5208 can be perpendicular to the edge surface of the mobile device. As with the mobile device 5202 depicted in fig. 45C, the eject tool 5216 can be inserted through an eject opening 5218 in the housing of the mobile device 5222 in the direction of an axis that is at an angle 5224 from the direction of movement of the sliding tray 5214.

Some mechanical components may be utilized to implement an apparatus that converts the force generated by the insertion of the ejection tool 5206/5216 into the ejection opening 5208/5218 into a force that pushes the sliding tray 5204/5214 outward. The device can accommodate repeated ejection, removal, and reinsertion of a sliding tray 5204/5214 (or any similar flat object that can slide along a guide rail outward from the mobile device 5202/5222). Due to the limited amount of space available in the device, the apparatus may be designed to convert the shorter pushing force of the ejection tool 5216 to a longer pushing force against the slide tray 5204/5214, thereby ejecting the slide tray 5204/5214 a sufficient amount to enable a user to easily remove the slide tray 5204/5214 from the mobile device 5202/5222. Since the space available in the mobile device 5202/5222 housing for receiving the device may be limited, the device may include relatively small components made of a sturdy material to withstand the forces experienced upon repeated ejections. One or more surfaces of the component may be coated with a lubricant to ensure smooth operation. For example, the distance that the ejection end of the arm pushes the tray out as the arm rotates is increased by at least 1.5 times as compared to the distance that the ejection tool is pushed toward the force-bearing component.

Although a sliding tray is described herein in the exemplary embodiment, any substantially flat object may be ejected using the apparatus and methods described herein. The flat object may comprise a plurality of parts, for example a tray which may support a second flat object, such as a memory card or a Subscriber Identity Module (SIM) card for use in a mobile communication device. The flat object may include a recessed area, a joint, a hollow area, an open portion, and other features that may provide an area for pushing and pulling the flat object from the mobile device housing and guiding the flat object when ejected or inserted into the mobile device housing. The use of a sliding tray is not intended to be particularly limiting herein, and those skilled in the art will appreciate that the flat object includes equivalents suitable for ejection and insertion in a mobile device.

Fig. 46 illustrates a perspective view of a representative embodiment of an ejection apparatus arranged to eject the sliding tray 5301, including the tray body 5302 and the tray contact area 5303, through an edge surface 5304 of a mobile device (not shown). The apparatus can include a first pivot element (also referred to as a crank) 5306 that can receive ejection tool 5308 in ejection tool receiving area 5310. The ejection tool 5308 can be inserted through an opening in the edge surface 5304 of the mobile device at an angle substantially perpendicular to the edge surface 5304 of the mobile device. Edge surface 5304 can be angled or curved relative to the top surface of the mobile device, such that the insertion direction of ejection tool 5308 is generally not parallel to the top surface of the mobile device. The ejection tool receiving area 5310 may be shaped to capture a blunt end of the ejection tool 5308. In one embodiment, the ejection tool receiving area 5310 may be concave. In one embodiment, the ejection tool receiving area 5310 may be shaped in the form of a groove. In one embodiment, the ejection tool receiving area 5310 may be shaped to include at least two similar lobe-like areas.

First pivot element 5306 can rotate about first axis of rotation 5312, causing ejection tool receiving area 5310 to rotate upward, and causing cylindrical portion 5314 of first pivot element 5306, which is connected to connecting portion 5316, to rotate upward, such that connecting portion 5316 exerts force F on arm 5318_armThe arm 5318 is rotated about the second rotation axis 5320 (shown in fig. 46 and 47). The ejection end 5320 of the arm 5318 can contact the tray contact area 5303. The ejection force F as the arm 5318 rotates about the second axis of rotation 5320_ejectCan be applied directly to the tray contact area 5303 via the eject end 5320 to cause the tray 5301 to exert an eject force F_ejectIs moved in the direction of (2). Movement of the ejection end 5320 of the arm 5318 in contact with the tray contact area 5303 can push into the tray contact area 5303, thereby displacing the tray 5301 outward in a direction substantially parallel to the top surface of the mobile device past the edge surface 5304 of the mobile device. The tray contact area 5303 can be moved a distance beyond the edge 5304 of the mobile device sufficient to manually remove the sliding tray from the mobile device. In one embodiment, the bottom of the sliding tray contact area 5303 can include a recess sized and shaped to accept a removal tool (e.g., a finger or a portion of a fingernail) to grip and remove the tray 5301 from the mobile device. In one embodiment, the sliding tray can move about 0.9 mm to about 1.5 mm away from the edge surface 5322, depending on the size of the recess.

In one embodiment, the ejection tool insertion force may be about 6 newtons, while the ejection force of the sliding tray may be about 3 newtons. In one embodiment, the first pivot element 5306 and the arm 5318 can occupy a limited space within the mobile device housing, with a limited travel distance available for rotational movement. In one embodiment, any portion of the connecting portion 5316 may move a linear distance of less than 0.2 millimeters as the first pivot element 5306 rotates.

For multiple ejection and insertion operations of sliding tray 5301, first pivot element 5306 and arm 5318 may be manufactured from materials having sufficient strength to receive and transmit the required forces. In one embodiment, the material may comprise precipitation hardened martensitic stainless steel. In another embodiment, first pivot element 5306 and arm 5318 may be formed by a metal injection molding process and may be composed of a deposition hardened "613 type" alloy stainless steel having "condition 900". The precipitation hardening may also be considered as secondary hardening and age hardening and may be used to significantly increase the yield strength of the metal alloy.

Fig. 47 shows another perspective view of ejector 5300. Fig. 46 shows the entire apparatus from a different angle, which shows the relationship of the second rotation axis 5402 to the first rotation axis 5312 and the arm 5318. Which shows how the first pivot element 5306 is supported by the housing of the portable device. Also depicted is a sliding tray housing 5404, which is used to ensure that flat objects stored in sliding tray 5301 are always in their place regardless of the orientation of the device.

Fig. 47 illustrates an exploded view of ejector 5300, highlighting the relationship between the various elements. Fig. 48A shows in more detail how fastener 5502 is anchored in the device housing. Fig. 48B shows how the female receiving area 5310 and the crank 5306 are mounted in the device housing, and how the connecting portion 5316 moves and interacts with the crank 5306 while traversing the interior of the device housing. Fig. 48C shows how arm 5318 fits under crank 5316 and gives a better idea of how ejection end 5320 contacts tray contact area 5303.

Fig. 49 illustrates a perspective view of an exemplary embodiment of an ejection apparatus 5600 configured to eject a sliding tray 5301, including a tray body 5302 and a tray contact area 5303, through an edge surface 5304 of a mobile device (not shown). Ejection tool 5308 can be inserted into channel 5602 formed to house plunger 5604. Plunger 5604 can have body 5606 formed to fit snugly within channel 5602 and be less likely to fall out of channel 5602 because the insertion hole of the ejection tool can be made narrower than the width of plunger 5604. In one embodiment, plunger 5604 can have a head 5608 integrally formed with body 5606. In one embodiment, head 5608 can be shaped to include an angled surface 5610 that can make directional contact with an arm input location 5612 of an arm 5614 pivotally connected to a housing of a portable device by way of fastener 5616. In one embodiment, angled surface 5610 may be shaped in such a way as to redirect movement of ejection tool 5308 normal to a surface of the portable device housing such that force F is_armMay be substantially exactly parallel to the upper (or bottom) surface of the portable device. When arm input position 5612 is applied to arm 5614, force F_armArm 5614 may be rotated about rotational axis 5618 at fastener 5616. In one embodiment, rotation of arm 5614 about rotation axis 5618 may move ejection end 5620 of arm 5614 in a direction substantially opposite arm input position 5612 of arm 5614. In one embodiment, ejection end 5620 can be shaped to conform to tray contact area 5303 of tray 5301 such that movement of ejection end 5620 can move tray 5301 a predetermined distance from edge 5304 to expose a preselected amount of tray contact area 5303, and in particular, the indentation of tray 5301. In one embodiment, the predetermined distance may be on the order of about 0.9 to about 1.5 millimeters, depending on the amount of exposure desired for the recess in the tray 5301. The distance is sufficient to allow a user to easily remove the tray with a fingertip.

Fig. 50 shows another perspective view of the ejection device 5600. Fig. 50 shows the device from a different angle, showing the relationship of the axis of rotation 5618 to the arm 5614. Fig. 50 shows how fastener 5616 is attached to the device housing. Also depicted is a sliding tray housing 5404, which is used to ensure that flat objects stored in tray 5301 are always in their place regardless of the orientation of the device.

Fig. 51A-51C illustrate exploded views of ejection device 5600, highlighting the relationship between the various elements. Fig. 51A shows a cross-section of plunger 5604 and how it is installed in channel 5602 in more detail. Fig. 51B shows how fastener 5616 passes through arm 5614 and is anchored to the device housing. Fig. 51C shows how the eject end 5320 contacts the tray contact area 5303.

Fig. 52 illustrates a perspective view of a representative embodiment of an ejection apparatus 5900 configured to eject a sliding tray 5301, including a tray body 5302 and a tray contact area 5303, through an edge surface 5304 of a mobile device (not shown). Ejection apparatus 5900 operates ejection tray 5301 in substantially the same manner as apparatus 5600, except that the plunger has been eliminated so that ejection tool 5308 directly applies ejection force F_armThe ejection tool applied to arm 5614 contacts area 5902, thereby reducing the number of components required.

Fig. 53 shows another perspective view of the ejector 5900. Fig. 53 shows the device from a different angle, showing the relationship of the axis of rotation 5618 to the arm 5614. Fig. 53 shows how fastener 5616 is attached to the device housing. Also depicted is a sliding tray housing 5404, which is used to ensure that flat objects stored in sliding tray 5301 are always in their place regardless of the orientation of the device.

Fig. 54A-54C show exploded views of ejector 5900, highlighting the relationship between the various elements. Fig. 54A shows in more detail the cross section of ejection tool contact region 5902 and how it aligns with channel 5602. Fig. 54B shows how fastener 5616 passes through arm 5614 and is anchored to the device housing. Fig. 54C shows how ejection end 620 of arm 5318 contacts tray contact area 5303.

Fig. 55 shows a flow chart detailing a manufacturing process 51200 for mounting a flat object ejector to a mobile device. Process 51200 begins at step 51202 by receiving a flat object ejector assembly. The flat object ejector assembly may comprise any of the three embodiments described above. In step 51204, a mobile device housing is received. The mobile device may include, for example, a smartphone, a tablet device, a portable media player, and the like. In step 51206, the flat object ejector assembly is installed within and attached to the mobile device housing.

FIG. 56 illustrates steps of a method of ejecting a flat object from a mobile device housing in a representative embodiment. These steps illustrate the process for performing the steps of the most complex embodiment. The flat object may comprise a memory card, a tray that can support a SIM card, or the like. In step 51302, a device in a mobile apparatus can receive an ejection tool inserted along a first axis. The ejection tool may be received in the female portion of the first pivot member. In one embodiment, the insertion direction of the ejection tool may be along an axis perpendicular to the center of the opening in the mobile device housing. The housing of the mobile device may be shaped along a curved surface in the area around the opening. In one embodiment, the first axis of insertion may not be parallel to the top or bottom surface of the mobile device housing. The first axis may also be non-parallel to a circuit board inside the mobile device housing adjacent the opening. The first pivot element may be rotated about a first axis of rotation in response to insertion of the ejection tool in step 51304. The first pivot member may engage a link 51306 connected to the arm. In step 51308, rotation of the first pivot element can impart an ejection force F_ejectIs applied to the arm through the connection such that the arm rotates about a second axis substantially perpendicular to the first axis in 51310. Rotation of the arm in 51312 causes the ejection force F_ejectThe SIM tray is ejected.

Fig. 57 illustrates a top view 6300 of a representative embodiment of an apparatus configured to eject a sliding tray 6326 through an edge surface 6322 of a mobile device (not shown). The apparatus may include a first pivot element 6302 that may receive ejection tool 6328 in ejection tool receiving area 6318 (the opposite side of the top view shown). The ejection tool may be inserted through an opening in the mobile device edge surface 6322 at an angle substantially perpendicular to the mobile device edge surface 6322. Edge surface 6322 may form an angle or curve relative to the mobile device top surface, and thus the insertion direction of ejection tool 6328 may not be parallel to the mobile device top surface at all. Ejection tool receiving area 6318 may be shaped to capture a blunt end of an ejection tool. In one embodiment, ejection tool receiving area 6318 may be concave.

The first pivot element 6302 is able to rotate about the first rotation axis 6324 such that the receiving region 6318 is tilted upward and the cylindrical portion 6306 of the first pivot element 6302 is tilted downward toward the lever portion 6308 of the second pivot element 6304. The cylindrical portion 6306 may be continuously connected to the U-shaped portion of the first pivot member 6302, and the cylindrical portion 6306 and the U-shaped portion of the first pivot member 6302 may together enclose the lever portion 6308 of the second pivot member 6304. As the first pivot element 6302 rotates, the cylindrical portion 6306 of the first pivot element 6302 may press the lever portion 6308 of the second pivot element 6304, thereby causing the second pivot element 6304 to rotate about the second rotation axis 6316. The U-shaped portion and the cylindrical portion 6306 of the first pivot element 6302 may enclose the lever portion 6308 of the second pivot element 6304 to minimize lateral translation of the second pivot element 6304 along the second rotation axis 6316.

The plate-like portion 6310 of the second pivot element 6304 may be in contact with the back of the sliding tray front end 6312 and, as the second pivot element 6304 rotates about the second rotation axis 6316, the plate-like portion 6310 may be pushed toward the sliding tray 6326, thereby displacing the sliding tray body 6314 and the sliding tray front end 6312 outwardly past the mobile device edge surface 6322. The sliding tray 6326 is displaceable in a direction substantially parallel to the top surface of the mobile device. The sliding tray body 6314 and sliding tray front end 6312 can be moved out of the mobile device housing a distance sufficient to manually remove the sliding tray from the mobile device. In one embodiment, the sliding tray front end 6312 may include a notch that accepts a removal tool (e.g., a portion of a finger or fingernail) to grip and remove the sliding tray from the mobile device. The lever portion 6308 of the second pivot element 6304 may amplify the force of the ejection tool 6328 against the first pivot element 6302, generating a force of the plate-like portion 6310 of the second pivot element 6304 against the slide tray 6326 that may be greater than the force of the ejection tool 6328 against the ejection tool receiving area 6318 of the first pivot element 6302. In one embodiment, the ejection force of the sliding tray may be at least 1.5 times the insertion force of the ejection tool. In one embodiment, the insertion force of the ejection tool may be about 10 newtons, while the ejection force of the sliding tray may be about 20 newtons. In one embodiment, the first and second pivot elements 6302, 6304 may occupy a limited space within the mobile device housing, with a limited movement distance available for rotational movement. In one embodiment, any portion of the first and second pivot elements 6302, 6304 may move a linear distance of less than 20 millimeters when rotated.

The device may also include a foam block 6320 adjacent to the second pivot element 6304. The foam piece 6320 may be compressed by the leading end portion of the second pivot element 6304 as the second pivot element 6304 rotates to eject the sliding tray 6326 in response to the force of the ejection tool 6328 on the first pivot element 6302. In a "closed" neutral home position, in which the sliding tray 6326 may be fully included in the housing of the mobile device, the plate-like portion 6310 of the second pivot element 6304 may be in a position substantially perpendicular to the sliding tray body 6314 and parallel to the back portion of the sliding tray front end 6312, where the plate-like portion 6310 may contact and push against the second pivot element 6304 as it rotates. In an "open" eject position, in which the sliding tray may be partially included in the housing of the mobile device and partially extend outside the mobile device housing, the plate-like portion 6310 of the second pivot element 6304 may be rotatable at an angle that may not be perpendicular to the sliding tray body 6314 nor parallel to the back portion of the sliding tray front end 6312. When the ejection tool 6328 is removed from the mobile device housing, thereby releasing the force on the first pivot element 6302 that is capable of rotating the first pivot element 6302 (which in turn may rotate the second pivot element 6304), the foam piece 6320 may decompress to press against the leading end portion of the second pivot element 6304. The decompression of the foam piece 6320 may cause the second pivot element 6304 to rotate back toward the "closed" neutral home position. The plate-like portion 6310 of the second pivot element 6304 may be configured such that the sliding tray body 6314 cannot contact the plate-like portion 6310 of the second pivot element 6304 after decompression of the foam bun 6320 when the sliding tray 6326 is reinserted into the mobile device housing. Rotation of the plate-like portion 6310 of the second pivot element 6304 may thus be used to at least partially eject the sliding tray 6326 from the mobile device without contacting the sliding tray 6326 when reinserting the mobile device.

Fig. 58 illustrates a perspective view 6400 of a portion of the apparatus depicted in fig. 57, configured to eject a sliding tray from a housing of a mobile device. First pivot element 6302 may receive ejection tool 6328 into ejection tool receiving area 6318 in the direction of the first axis. The insertion direction of ejection tool 6328 may be perpendicular to at least a portion of the edge surface of the mobile device housing (not shown). The direction may be non-parallel to the top surface of the mobile device, non-parallel to the direction of movement of a sliding tray in the mobile device, or non-parallel to a circuit board in the mobile device that is above or below the sliding tray. The force of the ejection tool 6328 against the ejection tool receiving area 6318 of the first pivot element 6302 may cause the first pivot element 6302 to rotate in a counter-clockwise direction about the first rotation axis 6324. Counterclockwise rotation of the first pivot element 6302 may contact the cylindrical portion 6306 of the first pivot element 6302 with the lever portion 6308 of the second pivot element 6304. In one embodiment, the lever portion 6308 of the second pivot element 6304 may be curved. As the first and second pivot elements 6302/6304 rotate counterclockwise about the first and second rotation axes 6324/6316, respectively, the cylindrical portion 6306 of the first pivot element 6302 may contact and slide along the curved lever portion 6308 of the second pivot element 6304.

As the second pivot element 6304 rotates about the second rotation axis 6316, the plate-like portion 6310 of the second pivot element 6304 may contact the back portion of the front end 6312 of the sliding tray, thereby pushing the sliding tray in an outward direction from the mobile device housing where the sliding tray may be located. The plate-like portion 6310 may start at a "neutral" home position, which may be perpendicular to the top surface of the mobile device case and parallel to the back portion of the slide tray front end 6312 that may come into contact with the plate-like portion 6310 when the slide tray is ejected. Upon rotation, the plate portion 6310 may be in an "inclined" eject position that may not be perpendicular to the top surface of the housing (i.e., not perpendicular to the direction of movement of the sliding tray). The sliding tray 6326 may be ejected a distance from the mobile device case sufficient for the mobile device user to access the sliding tray 6326 by manually pulling the sliding tray 6326 out of the mobile device. The sliding tray front end 6312 may include a notch 6406 along the bottom surface that allows a user to insert a removal tool to grasp the sliding tray. A representative removal tool may be a finger or fingernail of a user of the mobile device.

Rotation of the second pivot element 6304 in response to a force applied by the ejection tool 6328 to the first pivot element 6302 may also push the contact portion 6404 of the second pivot element 6304 against the surface of the foam piece 6320, thereby compressing the foam piece 6320. Without the foam block 6320, the second pivot element 6304 may still rotate with the slab portion 6310 in the "tilted" position after removal of the ejection tool 6328. A portion of the sliding tray body 6314 may contact the plate portion 6310 in this "tilted" position when the sliding tray 6326 is reinserted into the mobile device housing. To avoid such contact between the sliding tray 6326 and the plate-like portion 6310 of the second pivot member 6304, upon removal of the ejection tool 6328, the foam piece 6320 may decompress against the contact portion 6404 of the second pivot member 6304, thereby rotating the second pivot member 6304 in a clockwise direction about the second rotation axis 6316. This clockwise rotation may return the plate-like portion 6310 of the second pivot element 6304 to a "neutral" position. When the slide tray 6326 is inserted into the mobile device, the slide tray body 6314 and the slide tray front end 6312 may be positioned so as not to contact the plate-like portion 6310 of the second pivot member 6304, allowing smooth insertion without irregular contact or scratching of the plate-like portion 6310 with the slide tray 6326 (or with a flat object such as a memory card contained therein). The foam block 6320 may also minimize excessive movement of the first and second pivot members 6302/6304 relative to each other to minimize a "rattling" sound as the mobile device changes direction. When installed, the sliding tray 6326 may be positioned adjacent to a circuit board and/or connector in the mobile device. In one embodiment, the sliding tray 6326 may include a Subscriber Identity Module (SIM) card that is positioned in contact with at least a portion of a circuit board and/or connector in the mobile device, thereby providing an electrical connection path between the SIM card and circuitry within the mobile device.

For multiple ejection and insertion operations of the sliding tray 6326, the first and second pivot members 6302/6304 may be made of a material having sufficient strength to receive and transmit the required force. In one embodiment, the first and second phase shaft elements 6302/6304 may be fabricated from a precipitation hardened martensitic stainless steel. In one embodiment, the first and second pivot members 6302/6304 may be formed by a metal injection molding process and may be constructed of a deposition hardened "613 type" alloy stainless steel having "Condition 900". The precipitation hardening may also be considered as secondary hardening and age hardening and may be used to significantly increase the yield strength of the metal alloy. Since the cylindrical portion 6306 of the first pivot member 6302 may contact at least a portion of the surface of the lever portion 6308 when rotated, at least a portion of the cylindrical portion 6306 and at least a portion of the lever portion 6308 may be coated with a dry film lubricant. In one embodiment, the entire first pivot member 6302 and the entire second pivot member 6304 may be coated with a dry film lubricant. The dry lubricant and the curved surfaces of the lever portion 6308 and the curved surface of the cylindrical portion 6306 may provide a smooth contact as the cylindrical portion 6306 of the first pivot member 6302 slides along the lever portion 6308 of the second pivot member 6304 as the first and second pivot members 6302/6304 rotate about the first and second rotational axes 6324/6316, respectively. In one embodiment, the dry lubricant coating may be applied by dipping the first and second pivot members 6302/6304 in an aqueous solution comprising an alcohol and a dry lubricant, wherein the alcohol is capable of evaporating while leaving the dry lubricant coating the metal alloy portions of the first and second pivot members 6302/6304. The dry lubricant on the metal alloy portions of the first and second pivot members 6302/6304 may improve the performance of the ejection device, including smooth operation with minimal friction between the contacting surfaces. The dry film coating eliminates migration of lubricant within the mobile device, avoids dust accumulation on the mobile components, and avoids contamination of other components contained in the mobile device with lubricant. In one embodiment, the ejector can withstand at least 2000 repetitions of ejection and insertion.

Fig. 59 shows an additional perspective view 6500 of an embodiment of an apparatus for sliding tray ejection in a mobile device. As described above, the ejection tool 6328 may be inserted through an opening in the mobile device housing and may be received in the ejection tool receiving area 6318 of the first pivot element 6302. The ejection tool 6328 may drive the first pivot element 6302 to rotate about the first rotation axis 6324 such that the cylindrical portion 6306 of the first pivot element 6302 contacts and slides along the curved lever portion 6308 of the second pivot element 6304. The second pivot element 6304 may in turn rotate about the second rotation axis 6316, thereby pushing the plate-like portion 6310 towards the back portion of the sliding tray front end 6312, thereby ejecting the sliding tray 6326 at least partially out of the mobile device housing. The sliding tray body 6314 may include a hollow area in which a memory card, such as a SIM card, may be mounted. The SIM card may electrically contact a circuit board located below (or above) the sliding tray 6326. As shown in fig. 59, the first rotation shaft 6324 and the second rotation shaft 6316 may be parallel to each other, and a shaft in the insertion direction of the ejection tool 6328 and a shaft in the moving direction of the slide tray 6326 may be non-parallel to each other during ejection. In one embodiment, the angle 408 between insertion of the ejection tool 6328 and ejection of the sliding tray 6326 may be approximately between 40 and 50 degrees. This included angle 408 may be dependent on the curvature of the edge surface of the housing at the point of insertion of ejection tool 6328.

Fig. 60 illustrates a bottom view 6600 of an embodiment of an apparatus for ejecting a sliding tray 6326 through a mobile device case. An ejection tool receiving area 6318 located on the bottom surface of the first pivot member 6302 may receive an ejection tool 6328 in a direction along the first axis. The first pivot element 6302 may be rotated to press the cylindrical portion 6306 of the first pivot element 6302 against the lever portion 6308 of the second pivot element 6304 and slide it along the lever portion 6308 of the second pivot element 6304. The plate-like portion 6310 (not shown) of the second pivot element 6304 may be rotated to push the sliding tray front end 6312 in a direction along the second axis. The first and second axes may be non-parallel to each other.

Fig. 61 and 62 show in detail a front perspective view 6700 and a rear side view 6800 of four elements included in one embodiment of an apparatus for ejecting a sliding tray 6326 through a mobile device housing. The slide tray 6326 includes a slide tray contact region 6710 at a rear portion of the slide tray front end 6312, where the plate-like portion 6310 of the second pivot element 6304 may contact it when rotating. The sliding tray body 6314 includes a hollow interior 6704 through which electrical contacts on a second flat object, such as a SIM card, may be brought into contact with a circuit board mounted beneath the sliding tray 6326. A bracket 6706 along the inside edge of the sliding tray 6326 holds the SIM card in place. Rails 6708 along the outer edge of the sliding tray 6326 may guide the sliding tray 6326 when moving inward or outward from the mobile device.

The first pivot element 6302 may include a lever catch portion 6702 that may enclose the lever portion 6308 of the second pivot element when assembled together in the mobile device. As the first pivot element 6302 rotates in response to an ejection tool 6328 (not shown) being pushed toward an ejection tool receiving area 6318 of the first pivot element 6302, the cylindrical portion 6306 of the first pivot element 6302 may press against and slide along the lever portion 6308. The second pivot element 6304 may be rotated to press the plate-like portion 6310 against the slide tray contact area 6710 of the slide tray 6326, thereby ejecting the slide tray 6326 at least partially out of the mobile device housing. The foam piece 6320 may abut against the front end portion 6712 of the lever portion 6308 on the second pivot element 6304. When rotated, the second pivot member 6304 may press the front end portion 6712 against the foam block 6320. When the ejection tool 6328 is removed, the foam piece 6320 may be decompressed relative to the front end portion 6712, causing the second pivot element 6304 to rotate back to the original "neutral" home position. Such rotation may return the plate-like portion 6310 to the vertical direction from the "tilted" position in which the slide tray 6326 is ejected out of the mobile apparatus.

Fig. 63 shows a front view 6900 and a rear view 6910 of the elements of the apparatus for ejecting a sliding tray shown in fig. 62 and 61, assembled together in a "neutral" home position when the sliding tray 6326 is fully insertable into the mobile device housing. The front face of the sliding tray front end 6312 may be flush with the mobile device housing outer surface. The plate-like portion 6310 may be placed vertically adjacent to the slide tray contact area 6710 of the slide tray 6326. In one embodiment, the plate-like portion 6310 may approach without contacting the sliding tray contact area 6710 in the "neutral" home position. In another embodiment, the plate-like portion 6310 may contact the sliding tray contact area 6710 in the "neutral" home position, but does not provide sufficient force to eject the sliding tray 6326 out of the mobile device housing. The ejection tool receiving area 6318 of the first pivot element 6302 may be angled to receive the ejection tool 6328 through an opening in the housing that is perpendicular to the surface of the mobile device housing. The lever portion 6308 of the second pivot member 6304 may be surrounded by the lever catch portion 6702 of the first pivot member 6302, thereby minimizing lateral movement of the first and second pivot members 6302/6304 in the mobile device housing.

Figure 64 shows a left view 61000 and a right view 61010 of the elements of the device for ejecting a sliding tray shown in figures 61 and 62, assembled together in a "neutral" home position. Insertion of the ejection tool 6328 into the ejection tool receiving area 6318 of the first pivot element 6302 may cause the first pivot element 6302 to rotate and contact the lever portion 6308 of the second pivot element, thereby rotating the plate-like portion 6310 of the second pivot element 6304 and causing the plate-like portion 6310 of the second pivot element 6304 to contact the contact area 6710 of the sliding tray front end 6312, ejecting the sliding tray 6326 from the mobile device housing. The insertion of the ejection tool 6328 may be perpendicular (orthogonal) to the surface of the sliding tray front end 6312, which may be closely aligned with the mobile device housing outer surface. The slide tray 6326 can be ejected along an orientation axis different from the insertion orientation axis of the slide tray 6328. In one embodiment, the sliding tray 6326 pops out in a direction parallel to the top surface of the mobile device. When mounted to the mobile device, the sliding tray body 6314 may be substantially parallel to the circuit board below the sliding tray 6326.

Fig. 65 shows a perspective view of selected elements of the apparatus shown in fig. 62-64, assembled together, in a neutral "home" position, as might be present with a unit mounted in a mobile device housing. The plate-like portion 6310 of the second pivot element 6304 may be in a substantially upright position adjacent to the back portion of the sliding tray front end 6312. The foam piece 6320 may be partially compressed by placing the foam piece 6320 against the front end portion 6712 of the lever portion 6308 of the second pivot element 6304, but without exerting any significant pressure on the second pivot element 6304 in the neutral "home" position. The sliding tray front end 6312 may include a notch by which a user of the mobile device may grasp and extract the sliding tray 6326 from the mobile device housing.

Fig. 66 shows a perspective view of the selection elements of the device shown in fig. 62-64, assembled together in an "ejected" position, as may occur with the first pivot element 6302 rotatable in response to pressure from the ejection tool 6328 (not shown). The cylindrical portion 6306 of the first pivot member 6302 may rotate and press the lever portion 6308 of the second pivot member causing the second pivot member 6304 to rotate and press the plate-like portion 6310 of the second pivot member 6304 against the back portion of the sliding tray front end 6312, thereby at least partially ejecting the sliding tray 6326 from the mobile device housing. As both the first and second pivot elements 6302, 6304 rotate, the cylindrical portion 6306 of the first pivot element 6302 may slide along the curved lever portion 6308 of the second pivot element 6304. The surface of the cylindrical portion 6306 of the first pivot member 6302 that may contact the lever portion 6308 of the second pivot member 6304 may be coated with a dry lubricant. Similarly, the curved surface of the lever portion 6308 of the second pivot member 6304 may also be coated with a dry lubricant. The dry lubricant coating can facilitate smooth movement of the contacted cylindrical portion 6306 of the first pivot member 6302 relative to the curved lever portion 6308 of the second pivot member 6304 and across the curved lever portion 6308 of the second pivot member 6304. In one embodiment, both the first pivot member 6302 and the second pivot member 6304 are integrally coated with a dry film lubricant. The foam pad 6320 may be compressed with the front end portion 6712 (the front side of the curved lever portion 6308) of the second pivot element 6304. The foam block 6320 may decompress when the pressure on the first pivot element 6302 is released (i.e., the ejection tool 6328 is removed), thereby causing the second pivot element 6304 to rotate back to the neutral "home" position. When the sliding tray 6326 is reinserted back into the mobile device housing, the plate-like portion 6310 in the neutral "home" position cannot directly contact the sliding tray body 6314 and the SIM card or sliding tray front end 6312 mounted in the sliding tray body 6314, and thus allows smooth operation without frictional contact between the plate-like portion 6310 of the second pivot element 6304 and the sliding tray 6326 or the flat object mounted therein.

The various aspects, embodiments, implementations or features of the described embodiments may be used alone or in any combination. The various aspects of the described embodiments may be implemented in software, hardware, or a combination of hardware and software. The described embodiments may also be embodied as computer readable code on a computer readable medium for controlling a manufacturing operation or 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 these specific details are not required in order to practice the present 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 embodiment was chosen and described in order to best explain the principles of the invention and its practical application, 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 in terms of several 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 manufacturing the integrated tube, it should be noted that it is not limiting and other manufacturing methods (e.g., injection molding) can 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.

The portable computing devices described herein may take many forms, such as a laptop computer, a tablet computer, and so on. The portable computing device may include at least a single piece housing. The one-piece shell may be machined from a single blank of material, such as aluminum. The one-piece housing may include a ledge having a surface for receiving the bezel bead and the cover. Corner brackets may be attached to the one-piece shell to improve the damage resistance of the shell.

A portable computing device is disclosed. The portable computing device may take many forms, such as a laptop computer, a tablet computer, and the like. The portable computing device may include a one-piece housing formed of a radio-opaque material with a cover formed of a radio-transparent material. To implement a wireless interface, an antenna stack may be provided that allows the antenna to be mounted to the bottom of the cover. Methods and apparatus are provided for enhancing wireless performance. For example, in one embodiment, the metal housing may be thinned to enhance antenna performance. As another example, a faraday cage may be formed around the speaker driver to enhance antenna performance. The battery assembly and the main logic board may be mounted directly to the substantially flat bottom wall with a plurality of additional elements disposed around the periphery of the battery assembly and the main logic board. A method and apparatus for machining an outer surface of a metal alloy case of a portable electronic device to form a combination of a flat edge surface, a curved edge surface, and a flat bottom surface is disclosed. The flat edge surface is ground by contacting a first flat portion of a rotating cutting tool along a first loop of a predetermined continuous helical path. The curved edge surface is ground by contacting the raised portion of the rotating cutting tool along the other loop of the first predetermined continuous helical path. The pitch of the vertical movement of the cutting tool is adjusted for each loop of the continuous helical path based on the resulting curvature of the metal alloy housing. The bottom surface is ground by contacting the flat portion of the cutting tool along a second predetermined alternating direction straight path.

An apparatus for ejecting a flat object out of a mobile device housing is disclosed. The device is arranged to receive an ejection tool along a first axis and eject the flat object along a second axis, wherein the first axis and the second axis are non-parallel. In one embodiment, the first axis is parallel to the top surface of the mobile device and the second axis is perpendicular to the curved edge surface of the mobile device. An apparatus for ejecting a flat object out of a mobile device housing is disclosed. The device is arranged to receive an ejection tool along a first axis and eject the flat object along a second axis, wherein the first and second axes are non-parallel. In one embodiment, the first axis is parallel to the top surface of the mobile device and the second axis is perpendicular to the curved edge surface of the mobile device. In one embodiment, the device includes a first pivot member to receive the ejection tool and rotate, thereby displacing a lever portion of a second pivot member. The second pivot member includes a plate-like member that contacts and ejects the flat object when the second pivot member rotates.

Claims (7)

1. A housing for an electronic device, comprising:

a first part having 1) a base coupled with adjoining sidewalls extending over the base to form an internal cavity, wherein a portion of an outer surface of the base and an inner surface portion of the base in the cavity are substantially planar and parallel to each other, the internal cavity configured to receive a plurality of electronic components associated with the electronic device, 2) each sidewall including a ledge extending from the sidewall toward an interior of the cavity, the ledge being substantially parallel to the planar inner surface portion, the ledge including a surface for receiving a bezel bead and a cover, wherein the first part is formed from a single blank of material,

a bracket mounted to and extending around a corner of the side wall adjacent to a ledge formed on the side wall, the bracket including a surface for receiving the bezel bead, the surface being aligned with and at approximately the same elevation as a surface on the ledge for receiving the bezel bead, for mounting the bezel bead and the corner portion of the cover to the bracket, wherein the bracket is configured to reduce impact damage to the electronic device caused by an impact at the corner, and a conductive foam located between the bracket and the first part for electrically grounding the bracket to the first part.

2. The enclosure of claim 1, wherein at least 90% of a volume of the single blank is removed during a process for forming the first part.

3. The enclosure of claim 1, further comprising: an opening in the bottom, wherein a groove including a ledge is formed around the opening in the interior cavity.

4. The housing of claim 3, further comprising an emblem laminate including an emblem insert coupled to a metal plate, wherein the emblem insert is shaped to fit through the opening and the metal plate is shaped to fit in the groove such that it can be coupled to a ledge.

5. The enclosure of claim 1, wherein the height of the enclosure from the exterior of the bottom portion to the top portion of the cover is less than about 9 millimeters.

6. The enclosure of claim 1, further comprising an antenna window formed of a radio transparent material, wherein the antenna window replaces a corresponding portion of the first piece of the enclosure.

7. The enclosure of claim 1, wherein the first part and the bracket are formed of metal and the cover is formed of glass.