Abstract:
A method for assembling an electronic device comprises inserting a thermal element into an electrical connector contained within a special volume defined by a constricted enclosure that comprises a housing of the electronic device. The spatial volume contains a printed circuit board and the electrical connector includes internal electrical contacts that are positioned proximate to solder connection pads on the printed circuit board when the electrical connector and the printed circuit board are contained within the constricted enclosure. Insertion of the thermal element heats the internal electrical contacts so that solder on the solder connection pads reflows to form solder connections respectively between the internal electrical contacts and the solder connection pads. Thereafter, the thermal element is removed from the electrical contact.

Description:
BACKGROUND OF THE INVENTION 
     An electronic device typically has an external housing which is made of plastic or metal. Within the external housing are various electrical components that are interconnected, such as with wires or solder connections. As portable electronic devices become smaller, the density of electrical components within housings of such electronic devices increases which makes assembly of such electronic devices even more tedious. 
     Conventionally, separate electrical components of an electrical device need to be electrically connected, such as through use of solder connections. These solder connections are formed using solder equipment before the external housing encloses the electrical components. However, since electronic devices continue to get smaller, there is a continuing need for improved approaches to assembly and interconnect separate electrical components to be enclosed by an electronic device housing. 
     SUMMARY OF THE INVENTION 
     The invention pertains to improve techniques for assembling electronic devices within housings. The improved techniques enable distinct electrical components of an assembly to be separately inserted into a tightly constrained enclosure. After the separate electrical components have been inserted into the housing, the separate electrical components can be electrically connected. Advantageously, the improved techniques enable electrical components of an assembly to be separately inserted into a tightly constrained enclosure when a sub-assembly of such products prior to insertion is not practicable or feasible. 
     The invention may be implemented in numerous ways, including, but not limited to, as a system, device, apparatus, or method. Example embodiments of the present invention are discussed below. 
     As a method for assembling an electronic device having a constricted enclosure, one embodiment of the invention can, for example, include at least: providing a constricted enclosure including an electrical connector and a printed circuit board, where the electrical connector includes internal electrical contacts that are positioned proximate to solder connection pads on the printed circuit board when the electrical connector and the printed circuit board are contained within the constricted enclosure; inserting a thermal element into the electrical connector to heat the internal electrical contacts so that solder provided on the solder connection pads reflows to form solder connections respectively between the internal electrical contacts and the solder connection pads; and thereafter removing the thermal element from the electrical connector. 
     As a method for assembling an electronic device having a constricted enclosure, another embodiment of the invention can, for example, include at least: providing a constricted enclosure including an electrical connector and a substrate for electronic components, where the electrical connector includes internal electrical contacts that are positioned adjacent solder connection pads on the substrate when the electrical connector and the substrate are positioned within the constricted enclosure, the electrical connector further including an opening to receive and establish an electrical connection with a counterpart connector; inserting a probe into the opening of the electrical connector to cause heating of solder provided on the solder connection pads thereby forming solder connections respectively between the internal electrical contacts of the electrical connector and the solder connection pads of the substrate; and thereafter removing the probe from the opening of the electrical connector. 
     Another embodiment of the invention can pertain to an electronic device assembled in accordance with either the above-noted methods for assembling an electronic device. 
     As an electronic device assembly station, one embodiment of the invention can, for example, include at least: an external housing for a portable electronic device, the external housing including an electrical connector and a substrate for electronic components, where the electrical connector includes electrical contacts that are positioned adjacent solder connection pads on the substrate when the electrical connector and the substrate are contained within the external housing, the electrical connector further including a connector opening to receive and establish an electrical connection with a counterpart connector, the connector opening being adjacent a first housing opening to allow insertion of the counterpart connector into the connector opening; and means for inducing heat to the solder at the solder connection pads from internal to the external housing by way of the first housing opening and the connector opening. 
     As a method for assembling an electronic device having a confined housing, one embodiment of the invention can, for example, include at least: providing a confined housing having an opening for an electrical connector, the confined housing including at least a first electrical component and a second electrical component, the first electrical component having at least a first connection area, the second electrical component having at least a second connection area, the first connection area and the second connection area are aligned proximate one another when placed within the confined housing, at least one of the first connection area and the second connection area have a quantity of solder; inserting a probe into the opening of confined housing for the electrical connector to cause heating of at least a portion of the quantity of solder thereby forming solder connections respectively between the first connection area and the second connection area; and thereafter removing the probe from the opening of the confined housing. 
     Various aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, in which: 
         FIGS. 1A  and  FIG. 1B  are perspective views of a portable electronic device  100  according to one embodiment of the invention. 
         FIG. 2  is a flow diagram of a device assembly process according to one embodiment of the invention. 
         FIG. 3  is a flow diagram of a device assembly process according to one embodiment of the invention. 
         FIG. 4  is an assembly view of an electronic device according to one embodiment of the invention. 
         FIGS. 5A and 5B  are cross-sectional views of an electronic device according to one embodiment of the invention. 
         FIGS. 6A and 6B  are cross-sectional views of the electronic device for assembly processing according to one embodiment of the invention. 
         FIG. 6C  is a cross-sectional view of the electronic device for assembly processing according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention pertains to improve techniques for assembling electronic devices within housings. The improved techniques enable distinct electrical components of an assembly to be separately inserted into a tightly constrained enclosure. After the separate electrical components have been inserted into the housing, the separate electrical components can be electrically connected. Advantageously, the improved techniques enable electrical components of an assembly to be separately inserted into a tightly constrained enclosure when a sub-assembly of such products prior to insertion is not practicable or feasible. 
     In one embodiment, the invention enables assembly of an electronic device including at least a printed circuit board and an electrical connector within a tightly constrained housing, whereby the printed circuit board and the electrical connector can be soldered together after being separately inserted into the tightly constrained housing. 
     The invention is suitable for a wide variety of electronic devices that make use of a constrained enclosure or housing. The invention is, however, particularly well suited for portable electronic devices. Examples of portable electronic devices include portable media players, mobile communication devices (e.g., mobile telephones, pagers, etc.), device controllers (e.g., remote controllers), or personal digital assistants. 
     Embodiments of the invention are discussed below with reference to  FIGS. 1A-6C . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. 
       FIG.1A  is a rear perspective view of a portable electronic device  100  and  FIG. 1B  is a front perspective view of the portable electronic device  100 , according to one embodiment of the invention. The portable electronic device  100  has a housing  102  that sets an outer configuration and appearance for the portable electronic device  100 . The housing  102  also serves to enclosed electrical components of the portable electronic device. The housing  102  includes an opening  104  at one end that permits electrical components to be inserted into the housing  102 . The housing  102  can also include a connector opening  106  (connector receptacle) for receiving a removable connector. The removable connector can, for example, be a peripheral connector (e.g., USB connector), an audio jack, or a power plug. Although the housing  102  has a rectangular shape, it should be understood that the shape can vary widely, such as due to size, type, design, and/or materials. 
     For design and/or manufacturing reasons, it may be important to insert separate components into the housing  102  for the portable electronic device  100 . However, doing so can lead to a difficultly in electrically interconnecting the separate components after they have been provided within the housing  102 , particularly when the housing  102  is constrained to be aggressively small. For example, in a tightly constrained housing, if the interconnecting is done with solder connections, there may not be adequate clearance to permit conventional soldering techniques to be utilized. Hence, according to embodiments of the invention, techniques for electrically interconnecting separate components after the components are provided within the housing  102  are discussed below. 
       FIG. 2  is a flow diagram of a device assembly process  200  according to one embodiment of the invention. The device assembly process  200  can represent a process to assemble portions of an electronic device. The device assembly process  200  is advantageous for assembly of components of an electronic device, such as a portable electronic device, within a confined housing. 
     The device assembly process  200  can provide  202  a confined housing for the electronic device being assembled. The confined housing can represent an outer housing for the electronic device and provides an external appearance for the electronic device. The confined housing, in one embodiment, has an opening for an electrical connector. In other words, the electronic device being formed has a housing that contains an opening that is suitable to receive an electrical connector. Examples of electrical connectors that can be received in an opening in the confined housing include peripheral device plugs (e.g., USB connector), audio jacks, power plug, etc. 
     Next, a first electrical component and a second electrical component can be provided  204  within the confined housing. Here, the first electrical component and the second electrical component are, for example, inserted into the confined housing. Typically, the confined housing includes an opening (e.g., opening  104 ) through which the first and second electrical components can be provided  204  within the confined housing. After the first electrical component and the second electrical component are provided  204  within the housing, a first connection area of the first electrical component is aligned proximate to second connection area of the second electrical component. More particularly, since the first electrical component and the second electrical component are to be electrically interconnected, the respective connection areas of these electrical components are appropriately positioned so that interconnections can be established between the respective connection areas after the first and second electrical components have been inserted into the confined housing. The first electrical component can have additional connection areas that can be likewise respectively aligned proximate to additional connection areas of the second electrical component. 
     After the first and second electrical components have been provided  204  within the confined housing, a probe can be inserted  206  into the opening for the electrical connector. The probe, when provided within the opening for the electrical connector, can operate to facilitate formation of at least one connection between the first connection area and the second connection area. The at least one connection formed can provided at least electrical connection and possible also mechanical connection. In one implementation, the at least one connection is a solder connection. After the at least one connection has been formed, the probe can be removed  208  from the opening for the electrical connector in the confined housing. Following the block  208 , the device assembly process  200  can end. 
       FIG. 3  is a flow diagram of a device assembly process  300  according to one embodiment of the invention. The device assembly process  300  can represent a process to assemble portions of an electronic device. The device assembly process  300  serves to assemble portions of an electronic device, such as a portable electronic device, having a constricted enclosure (e.g., housing). 
     The device assembly process  300  can initially provide  302  a constricted enclosure for an electronic device. As an example, the constricted enclosure can represent an outer housing for the electronic device. The housing  102  for the portable electronic device  100  illustrated in  FIGS. 1A and 1B  is one example of the constricted enclosure. 
     Next, an electrical connector is inserted  304  into the constricted enclosure. The electrical connector can have leads (i.e., internal electrical contacts) that facilitate electrical connection to other components. The electrical connector has an opening that is capable of receiving a removable counterpart connector. The electrical connector is also secured  306  within the constricted enclosure. The constricted enclosure can include an opening that corresponds to the opening of the electrical connector, so that the opening of the electrical connector remains externally accessible even after being provided within the constricted enclosure. The electrical connector can be secured  306  to the constricted enclosure using a variety of different techniques, including adhesive or mechanically means, such as snaps, detents, screws and/or bolts. 
     Next, a substrate can be inserted  308  into the constricted enclosure. The substrate is inserted  308  into the constricted enclosure such that solder connection pads on the substrate are positioned adjacent to the leads of the electrical connector. In one embodiment, the leads of the electrical connector can be biased against the solder connection pads on the substrate. Additionally, in one embodiment, solder (e.g., solder balls) can be pre-deposited on the solder connection pads of the substrate before the substrate is inserted  308 . 
     Thereafter, a probe can be inserted  310  into the opening of the electrical connector. The probe can cause heating of solder previously provided on the solder connection pads of the substrate. Consequently, the probe causes solder connections to be respectively formed between the leads of the electrical connector and the solder connection pads of the substrate. After the appropriate solder connections have been established, the probe can be subsequently removed  312  from the opening of the electrical connector. Following the block  312 , the device assembly process  300  can end. However, further device assembly operation can be performed to insert additional electrical components into the constricted housing and/or to close an opening (e.g., opening  114 ) in the constricted enclosure, such as with an end cap, through which electrical components are inserted. 
       FIG. 4  is an assembly view of an electronic device  400  according to one embodiment of the invention. The electronic device  400  is assembled from a housing  402 , an electrical connector  404  and a Printed Circuit Board (PCB)  406 . 
     The housing  402  has a connector opening  408  at one end of the housing  402  and an insertion opening  410  at another end of the housing  402 . In one embodiment, the housing  402  is a unitary structure with only the connector opening  408  and the insertion opening  410 . The electrical connector  404  can be inserted into the housing  402  via the opening  410  of the housing  402 . The electrical connector  404  has an opening  412  for receiving a counterpart electrical connector (not shown). After the electrical connector  404  is inserted into the housing  402 , openings  414  in a forward section of the electrical connector  404  can be adjacent to an inner surface of the front end of the housing  402 . Screws  416  can be used to secure the electrical connector  404  within the housing  402 . In addition, once placed within the housing, the opening  412  of the electrical connector  404  is aligned with the connector opening  408  of the housing  402 . The electrical connector  404  also includes exposed leads  418 . 
     Next, the PCB  406  can be inserted into the housing  402  via the opening  410  of the housing  402 . The PCB  406  has a notch or cut-out  420  so that when inserted into the housing  402  a rearward section of the electrical connector  404  can fit within the notch or cut-out  420 . The PCB  406  can include a plurality of solder pads  422 . The solder pads  422  can include additional solder (e.g., solder bumps) for facilitating solder connections. The solder pads  422  can be positioned proximate to the notch or cut-out  420 . For example, each of the exposed leads  418  of the electrical connector  404  can be positioned such that they couple respectively to one of the solder pads  422 . In one implementation, the exposed leads  418  can be considered such that the leads  418  are bias against the solder pads  422 . 
     Once the electronic device  400  is assembled, the housing  402  is so tightly constrained, there is no conventional way to solder the exposed leads  418  of the electrical connector  404  to respective ones of the solder pads  422 . For instance, a soldering apparatus cannot gain access to the solder pads  422  once provided within the housing  402 . 
       FIGS. 5A and 5B  are cross-sectional views of an electronic device  500  according to one embodiment of the invention. The electronic device  500  has a housing  501  that contains various electrical components. The housing  501  includes an opening  502  at one side of the housing  501 . For example, the opening  502  can be similar to the opening  104  illustrated in  FIGS. 1A and 1B . The opening  502  allows the various electrical components of the electronic device  500  to be inserted into the housing  501 . As shown in  FIG. 5A , an electrical connector  504  has been inserted in the housing  501 . The electrical connector  504  has a front end  506  (forward section) that is secured to an inner surface of the housing  501 . Screws  508  can be used to secure the front end  506  of the electrical connector  504  to the inner surface of the housing  501 . The electrical connector  504  has a central opening  510  that extends through all or a substantial portion of the electrical connector  504 . The central opening  510  is designed to receive a removable electrical connector to make one or more electrical connections between the removable electrical connector and the electrical connector  504 . The housing  501  also has an opening  511  that corresponds or aligns with the central opening  510 . Accordingly, a removable electrical connector (e.g., jack, plug, etc.) can be inserted into the central opening  510  via the opening  511 . Exposed to the central opening  510  are leads  514  that facilitate connection to other electrical components within the housing  501 . For example, one electrical component that can be connected to the electrical connector  504  is a substrate, such as a Printed Circuit Board (PCB). 
     In  FIG. 5B , the electronic device  500 ′ represents a configuration of the electronic device  500  after a Printed Circuit Board (PCB)  512  has been inserted. As shown in  FIG. 5B , the PCB  512  can be inserted into the housing  501  via the opening  502  after the electrical connector  504  has already been inserted into the housing  501 . The PCB  512  can include connection pads  516 , such as solder connection pads. The leads  514  of the electrical connector  504  can be adjacent or aligned with the connection pads  516  of the PCB  512 . In one embodiment, the leads  514  can further be biased downward against respective ones of the connection pads  516  to provide a reliable connection. The PCB  512  can include a notch  518  that enable the PCB  512  to fit around the electrical connector  504 . 
     Although not shown in  FIGS. 5A and 5B , other electrical components can be provided within the housing  501  and can electrically connect with the electrical connector  504  and thus electrically connect to external devices via a removable electrical connector inserted into the central opening  510 . 
       FIGS. 6A and 6B  are cross-sectional views of the electronic device  500 ′ for assembly processing according to one embodiment of the invention. As shown in  FIG. 6A , a probe  600  can be inserted into the central opening  510  of the electrical connector  504 . As shown in  FIG. 6B , a forward portion  602  of the probe  600  is inserted into the central opening  510 . With the forward portion  602  of the probe  600  inserted into the central opening  510 , the leads  514  can be soldered to the respective connection pads  516 . More particularly, the probe  600  can apply or induce heating of the leads  514 . The probe  600  can apply or induce heating of the leads  514  by heating the probe  600 . Alternatively, the probe  600  can apply or induce heating by supplying electrical energy that also results in heating of the leads  514 . As the leads  514  are heated, solder provided on the connection pads  516  is heated by way of the leads  514 . Consequently, the solder provided on the connection pads  516  can reflow (e.g., melt) to establish soldered connections between the leads  514  and the connection pads  516 . The solder pads  516  can be pre-provided with additional solder on the connection pads  516 . Hence, the heating of the leads  514  can cause heating of the additional solder to thereby forming the soldered connections. 
       FIGS. 6C  is a cross-sectional view of the electronic device  500 ″ for assembly processing according to one embodiment of the invention. The electronic device  500 ″ represents the electronic device  500 ′ shown in  FIG. 6B  after the probe  600  has been inserted and then later removed from the central opening  510 . As shown in  FIG. 6C , solder connections  520  are established between the leads  514  of the electrical connector  504  and the solder pads  516  of the PCB  512 . 
     A portable electronic device as discussed herein may be a hand-held electronic device. The term hand-held generally means that the electronic device has a form factor that is small enough to be comfortably held in one hand. A hand-held electronic device may be directed at one-handed operation or two-handed operation. In one-handed operation, a single hand is used to both support the device as well as to perform operations with the user interface during use. In two-handed operation, one hand is used to support the device while the other hand performs operations with a user interface during use or alternatively both hands support the device as well as perform operations during use. In some cases, the hand-held electronic device is sized for placement into a pocket of the user. By being pocket-sized, the user does not have to directly carry the device and therefore the device can be taken almost anywhere the user travels. Even smaller, and thus more portable device, are wearable electronic devices. 
     The advantages of the invention are numerous. Different embodiments or implementations may, but need not, yield one or more of the following advantages. One advantage of certain embodiments of the invention is that very compact housings for portable electronic devices can be utilized. Separate components can be inserted into compact housing for enhanced density and then interconnect after being provided with a compact housing. Another advantage of certain embodiments of the invention is that an electrical connector (e.g., receptacle) provided within a housing for an electronic device can be used to interconnect (e.g., solder) components within the housing. 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.