Patent ID: 12261969

DETAILED DESCRIPTION

The present invention relates generally to electronic devices, and more particularly, to portable electronic devices such as handheld electronic devices.

The electronic devices may be portable electronic devices such as laptop computers or small portable computers of the type that are sometimes referred to as ultraportables. Portable electronic devices may also be somewhat smaller devices. Examples of smaller portable electronic devices include wrist-watch devices, pendant devices, headphone and earpiece devices, and other wearable and miniature devices. With one suitable arrangement, the portable electronic devices may be wireless electronic devices.

The wireless electronic devices may be, for example, handheld wireless devices such as cellular telephones, media players with wireless communications capabilities, handheld computers (also sometimes called personal digital assistants), remote controllers, global positioning system (GPS) devices, and handheld gaming devices. The wireless electronic devices may also be hybrid devices that combine the functionality of multiple conventional devices. Examples of hybrid portable electronic devices may include a cellular telephone that includes media player functionality, a gaming device that includes a wireless communications capability, a cellular telephone that includes game and email functions, and a portable device that receives email, supports mobile telephone calls, has music player functionality and supports web browsing. These are merely illustrative examples.

An illustrative portable electronic device in accordance with an embodiment of the present invention is shown inFIG.1. Device10ofFIG.1may be, for example, a handheld electronic device that supports 2G and/or 3G cellular telephone and data functions, global positioning system capabilities, and local wireless communications capabilities (e.g., IEEE 802.11 and Bluetooth®) and that supports handheld computing device functions such as internet browsing, email and calendar functions, games, music player functionality, etc.

Device10may have housing12. Antennas for handling wireless communications may be housed within housing12(as an example).

Housing12, which is sometimes referred to as a case, may be formed of any suitable materials including, plastic, glass, ceramics, metal, or other suitable materials, or a combination of these materials. In some situations, housing12or portions of housing12may be formed from a dielectric or other low-conductivity material. Housing12or portions of housing12may also be formed from conductive materials such as metal. An advantage of forming housing12from a dielectric material such as plastic is that this may help to reduce the overall weight of device10and may avoid potential interference with wireless operations.

In scenarios in which housing12is formed from metal elements, one or more of the metal elements may be used as part of the antennas in device10. For example, metal portions of housing12may be shorted to an internal ground plane in device10to create a larger ground plane element for that device10.

Housing12may have a bezel14. The bezel14may be formed from a conductive material and may serve to hold a display or other device with a planar surface in place on device10and to form an esthetically pleasing trim around the edge of device10. As shown inFIG.1, for example, bezel14may be used to surround the top of display16. Bezel14and other metal elements associated with device10may be used as part of the antennas in device10. For example, bezel14may be shorted to printed circuit board conductors, metal frame structures, or other internal ground plane structures in device10to create a larger ground plane element for device10.

Display16may be a liquid crystal display (LCD), an organic light emitting diode (OLED) display, or any other suitable display. The outermost surface of display16may be formed from one or more plastic or glass layers. If desired, touch screen functionality may be integrated into display16or may be provided using a separate touch pad device. An advantage of integrating a touch screen into display16to make display16touch sensitive is that this type of arrangement can save space and reduce visual clutter.

Display16(e.g., a touch screen) is merely one example of an input-output device that may be used with electronic device10. If desired, electronic device10may have other input-output devices. For example, electronic device10may have user input control devices such as button19, and input-output components such as port20and one or more input-output jacks (e.g., for audio and/or video). Button19may be, for example, a menu button. Port20may contain a multipin (e.g., a 30-pin) input-output connector (as an example). Openings22and24may, if desired, form speaker and microphone ports. Speaker port22may be used when operating device10in speakerphone mode. Opening23may also form a speaker port. For example, speaker port23may serve as a telephone receiver that is placed adjacent to a user's ear during operation. In the example ofFIG.1, display screen16is shown as being mounted on the front face of handheld electronic device10, but display screen16may, if desired, be mounted on the rear face of handheld electronic device10, on a side of device10, on a flip-up portion of device10that is attached to a main body portion of device10by a hinge (for example), or using any other suitable mounting arrangement.

A user of electronic device10may supply input commands using user input interface devices such as button19and touch screen16. Suitable user input interface devices for electronic device10include buttons (e.g., alphanumeric keys, power on-off, power-on, power-off, and other specialized buttons, etc.), a touch pad, pointing stick, or other cursor control device, a microphone for supplying voice commands, or any other suitable interface for controlling device10. Although shown schematically as being formed on the top face of electronic device10in the example ofFIG.1, buttons such as button19and other user input interface devices may generally be formed on any suitable portion of electronic device10. For example, a button such as button19or other user interface control may be formed on the side of electronic device10. Buttons and other user interface controls can also be located on the top face, rear face, or other portion of device10. If desired, device10can be controlled remotely (e.g., using an infrared remote control, a radio-frequency remote control such as a Bluetooth® remote control, etc.).

Electronic device10may have ports such as port20. Port20, which may sometimes be referred to as a dock connector, 30-pin data port connector, multipin input-output connector, input-output port, or bus connector, may be used as an input-output port (e.g., when connecting device10to a mating dock connected to a computer or other electronic device). Port20may contain pins for receiving data and power signals. Device10may also have audio and video jacks that allow device10to interface with external components. Typical ports include power pins to recharge a battery within device10or to operate device10from a direct current (DC) power supply, data pins to exchange data with external components such as a personal computer or peripheral, audio-visual jacks to drive headphones, a monitor, or other external audio-video equipment, a subscriber identity module (SIM) card port to authorize cellular telephone service, a memory card slot, etc. The functions of some or all of these devices and the internal circuitry of electronic device10can be controlled using input interface devices such as touch screen display16.

Components such as display16and other user input interface devices may cover most of the available surface area on the front face of device10(as shown in the example ofFIG.1) or may occupy only a small portion of the front face of device10.

A schematic diagram of an embodiment of an illustrative portable electronic device such as a handheld electronic device is shown inFIG.2. Portable device10may be a mobile telephone, a mobile telephone with media player capabilities, a handheld computer, a remote control, a game player, a global positioning system (GPS) device, a laptop computer, a tablet computer, an ultraportable computer, a hybrid device that includes the functionality of some or all of these devices, or any other suitable portable electronic device.

As shown inFIG.2, device10may include storage34. Storage34may include one or more different types of storage such as hard disk drive storage, nonvolatile memory (e.g., flash memory or other electrically-programmable-read-only memory), volatile memory (e.g., battery-based static or dynamic random-access-memory), etc.

Processing circuitry36may be used to control the operation of device10. Processing circuitry36may be based on a processor such as a microprocessor and other suitable integrated circuits. With one suitable arrangement, processing circuitry36and storage34are used to run software on device10, such as internet browsing applications, voice-over-internet-protocol (VOIP) telephone call applications, email applications, media playback applications, operating system functions, etc. Processing circuitry36and storage34may be used in implementing suitable communications protocols. Communications protocols that may be implemented using processing circuitry36and storage34include internet protocols, wireless local area network protocols (e.g., IEEE 802.11 protocols—sometimes referred to as Wi-Fi®), protocols for other short-range wireless communications links such as the Bluetooth® protocol, protocols for handling 3G communications services (e.g., using wide band code division multiple access techniques), 2G cellular telephone communications protocols, etc.

Input-output devices38may be used to allow data to be supplied to device10and to allow data to be provided from device10to external devices. Display screen16, button19, microphone port24, speaker port22, and dock connector port20are examples of input-output devices38.

Input-output devices38can include user input-output devices40such as buttons, touch screens, joysticks, click wheels, scrolling wheels, touch pads, key pads, keyboards, microphones, cameras, vibrators, etc. A user can control the operation of device10by supplying commands through user input devices40. Display and audio devices42may include liquid-crystal display (LCD) screens or other screens, light-emitting diodes (LEDs), and other components that present visual information and status data. Display and audio devices42may also include audio equipment such as speakers and other devices for creating sound. Display and audio devices42may contain audio-video interface equipment such as jacks and other connectors for external headphones and monitors.

Wireless communications devices44may include communications circuitry such as radio-frequency (RF) transceiver circuitry formed from one or more integrated circuits, power amplifier circuitry, passive RF components, antennas, and other circuitry for handling RF wireless signals. Wireless signals can also be sent using light (e.g., using infrared communications).

Device10can communicate with external devices such as accessories46, computing equipment48, and wireless network49as shown by paths50and51. Paths50may include wired and wireless paths. Path51may be a wireless path. Accessories46may include headphones (e.g., a wireless cellular headset or audio headphones) and audio-video equipment (e.g., wireless speakers, a game controller, or other equipment that receives and plays audio and video content), a peripheral such as a wireless printer or camera, etc.

Computing equipment48may be any suitable computer. With one suitable arrangement, computing equipment48is a computer that has an associated wireless access point (router) or an internal or external wireless card that establishes a wireless connection with device10. The computer may be a server (e.g., an internet server), a local area network computer with or without internet access, a user's own personal computer, a peer device (e.g., another portable electronic device10), or any other suitable computing equipment.

Wireless network49may include any suitable network equipment, such as cellular telephone base stations, cellular towers, wireless data networks, computers associated with wireless networks, etc. For example, wireless network49may include network management equipment that monitors the wireless signal strength of the wireless handsets (cellular telephones, handheld computing devices, etc.) that are in communication with network49.

To facilitate manufacturing operations, device10may be formed from two intermediate assemblies, representing upper and lower portions of device10. The upper or top portion of device10is sometimes referred to as a tilt assembly. The lower or bottom portion of device10is sometimes referred to as a housing assembly.

The tilt and housing assemblies may each be formed from a number of smaller components. For example, the tilt assembly may be formed from components such as display16and an associated touch sensor. The housing assembly may include a plastic housing portion and printed circuit boards. Integrated circuits and other components may be mounted on the printed circuit boards.

During initial manufacturing operations, the tilt assembly may be formed from its constituent parts and the housing assembly may be formed from its constituent parts (individual components and subassemblies). Because essentially all components in device10make up part of these two assemblies with this type of arrangement, the finished assemblies represent a nearly complete version of device10. The finished assemblies may, if desired, be tested. If testing reveals a defect, repairs may be made or defective assemblies may be discarded. During a final set of manufacturing operations, the tilt assembly may be inserted into the housing assembly. With one suitable arrangement, one end of the tilt assembly may be inserted into the housing assembly. The tilt assembly may then be rotated (“tilted”) into place so that the upper surface of the tilt assembly lies flush with the upper edges of the housing assembly.

As the tilt assembly is rotated into place within the housing assembly, clips on the tilt assembly can engage springs on the housing assembly. The clips and springs may form a detent that helps to align the tilt assembly properly with the housing assembly. Should rework or repair by necessary, the insertion process can be reversed by rotating the tilt assembly up and away from the housing assembly. During rotation of the tilt assembly relative to the housing assembly, the springs may flex to accommodate movement. When the tilt assembly is located within the housing assembly, the springs may press into holes in the clips to prevent relative movement between the tilt and housing assemblies. Rework and repair operations need not be destructive to the springs, clips, and other components in the device. This helps to prevent waste and complications that might otherwise interfere with the manufacturing of device10.

If desired, screws or other fasteners may be used to help secure the tilt assembly to the housing assembly. The screws may be inserted into the lower end of device10. With one suitable arrangement, the screws may be inserted in an unobtrusive portion of the end of device10so that they are not noticeable following final assembly operations. Prior to rework or repair operations, the screws can be removed from device10.

An exploded perspective view showing illustrative components of device10is shown inFIG.3.

Tilt assembly60(shown in its unassembled state inFIG.3) may include components such as cover62, touch sensitive sensor64, display unit66, and frame68. Cover62may be formed of glass or other suitable transparent materials (e.g., plastic, combinations of one or more glasses and one or more plastics, etc.). Display unit66may be, for example, a color liquid crystal display. Frame68may be formed from one or more pieces. With one suitable arrangement, frame68may include metal pieces to which plastic parts are connected using an overmolding process. If desired, frame68may be formed entirely from plastic or entirely from metal.

Housing assembly70(shown in its unassembled state inFIG.3) may include housing12. Housing12may be formed of plastic and/or other materials such as metal (metal alloys). For example, housing12may be formed of plastic to which metal members are mounted using fasteners, a plastic overmolding process, or other suitable mounting arrangement.

As shown inFIG.3, handheld electronic device10may have a bezel such as bezel14. Bezel14may be formed of plastic or other dielectric materials or may be formed from metal or other conductive materials. An advantage of a metal (metal alloy) bezel is that materials such as metal may provide bezel14with an attractive appearance and may be durable. If desired, bezel14may be formed from shiny plastic or plastic coated with shiny materials such as metal films.

Bezel14may be mounted to housing12. Following final assembly, bezel14may surround the display of device10and may, if desired, help secure the display onto device10. Bezel14may serve as a cosmetic trim member that provides an attractive finished appearance to device10.

Housing assembly70may include battery74. Battery74may be, for example, a lithium polymer battery having a capacity of about 1300 mA-hours. Battery74may have spring contacts that allow battery74to be serviced.

Housing assembly70may also include one or more printed circuit boards such as printed circuit board72. Housing assembly70may also include components such as microphone76for microphone port24, speaker78for speaker port22, and dock connector20, integrated circuits, a camera, ear (receiver) speaker, audio jack, buttons, SIM card slot, etc.

A top view of an illustrative device10is shown inFIG.4. As shown inFIG.4, device10may have controller buttons such as volume up and down buttons80, a ringer A/B switch82(to switch device10between ring and vibrate modes), and a hold button88(sleep/wake button). A subscriber identity module (SIM) tray86(shown in a partially extended state) may be used to receive a SIM card for authorizing cellular telephone services. Audio jack84may be used for attaching audio peripherals to device10such as headphone, a headset, etc.

An interior bottom view of device10is shown inFIG.5. As shown inFIG.5, device10may have a camera90. Camera90may be, for example, a two megapixel fixed focus camera.

Vibrator92may be used to vibrate device10. Device10may be vibrated at any suitable time. For example, device10may be vibrated to alert a user to the presence of an incoming telephone call, an incoming email message, a calendar reminder, a clock alarm, etc.

Battery74may be a removable battery that is installed in the interior of device10adjacent to dock connector20, microphone76, and speaker78.

A cross-sectional side view of device10is shown inFIG.6.FIG.6shows the relative vertical positions of device components such as housing12, battery74, printed circuit board72, liquid crystal display unit66, touch sensor64, and cover glass62within device10.FIG.6also shows how bezel14may surround the top edge of device10(e.g., around the portion of device10that contains the components of display16such as cover62, touch screen64, and display unit66). Bezel14may be a separate component or, if desired, one or more bezel-shaped structures may be formed as integral parts of housing12or other device structures.

An illustrative process for assembling device10from tilt assembly60and housing assembly70is shown inFIG.7.

As shown inFIG.7, the assembly process may begin by inserting upper end100of tilt assembly60into upper end104of housing assembly70. This process involves inserting tilt assembly60into housing assembly70along direction18until protrusions on the upper end of tilt assembly60engage mating holes on housing assembly70. Once the protrusions on tilt assembly60have engaged with housing assembly70, lower end102of tilt assembly60may be inserted into lower end106of housing assembly70. Lower end102may be inserted into lower end106by pivoting tilt assembly60about axis122. This causes tilt assembly60to rotate into place as indicated by arrow120.

Tilt assembly60may have clips such as clips112and housing assembly70may have matching springs114. When tilt assembly60is rotated into place within housing assembly70, the springs and clips mate with each other to hold tilt assembly60in place within housing assembly70.

Tilt assembly60may have one or more retention clips such as retention clips116. Retention clips116may have threaded holes that mate with screws108. After tilt assembly has been inserted into housing assembly, screws108may be screwed into retention clips116through holes110in housing assembly70. This helps to firmly secure tilt assembly60to housing assembly70. Should rework or repair be desired, screws108may be removed from retention clips116and tilt assembly60may be released from housing assembly70. During the removal of tilt assembly60from housing assembly70, springs114may flex relative to clips112without permanently deforming. Because no damage is done to tilt assembly60or housing assembly70in this type of scenario, nondestructive rework and repair operations are possible.

A lateral cross-sectional view of an illustrative device10is shown inFIG.8. As shown inFIG.8, cover glass62may be mounted on top of device10. An adhesive layer such as adhesive layer204may be formed between cover glass layer62and touch sensor64. Touch sensor64may be, for example, a capacitive multitouch sensor. Touch sensor64may be mounted above a display unit such as liquid crystal display unit66. Display unit66may be mounted above frame member206. Frame member206, which is sometimes referred to as a “midplate member” may be formed of a strong material such as metal (e.g., stainless steel type304). Frame member206may have vertical portions208. Vertical portions208may be attached to frame struts168by screws, other suitable fasteners, welds, adhesive, etc. Frame member206helps form a rigid platform for the components (such as display unit66, sensor64, and cover glass62) that are associated with the tilt assembly. In addition to providing structural support, midplate frame member206may also provide electrical grounding (e.g., for integrated circuits, printed circuit board structures, for antennas in wireless devices44, etc.).

Frame struts168may be attached to frame member166of frame68. For example, frame member166may be formed from plastic that is molded over frame struts168and that engages frame struts168in engagement region174. Frame protrusion148and gasket146may be used to separate glass62from bezel14.

Springs114may be welded or otherwise mounted to bezel14. When the tilt assembly is mounted in the housing assembly as shown inFIG.8, spring prongs182may protrude into the holes such as holes196that are formed by bent portions194in clips112. Springs114may also have one or more prongs that form grounding structures (e.g., to ground spring114and bezel14to midplate structures such as midplate member206and vertical portions208).

A perspective view of an interior portion of housing assembly70is shown inFIG.9. As shown inFIG.9, bezel14may be mounted to plastic housing portion12. Spring114may be mounted to housing assembly70by welding spring114to bezel14or by otherwise attaching spring114securely (e.g., using fasteners, adhesive, etc.). An advantage of using springs and a bezel that are formed of metal is that this allows secure attachment mechanisms such as welds to be used to attach the springs and allows electrical paths to be formed. Satisfactory welds may be facilitated by using metals that do not have disparate properties. As an example, springs114may be formed from the same material or substantially the same material as bezel14.

Springs such as spring114ofFIG.9may be formed from elongated spring members such as spring member180. Spring member180may be cut and bent to form spring prongs182and201(also sometimes referred to as spring members or springs). Spring prongs182and201may have any suitable shape. An advantage of forming spring prongs with relatively narrow widths (as measured along longitudinal housing dimension184) is that this allows the springs to flex during assembly. There may be any suitable number of spring prongs in device10. As an example, there may be one, two, three, four, five, or more than five spring prongs on the left and on the right sides of device10. Spring prongs182may mate with corresponding holes in clips112. Spring prongs such as spring prong201may be used as part of a grounding path. For example, spring201may be used to ground midplate structures206and208ofFIG.8to bezel14.

Springs may be mounted to the sides of housing12or may be mounted on other portions of housing12(e.g., on the edge of housing12that lies along lower end106ofFIG.7). An advantage of using springs and clips along the sides of device10is that this helps to ensure that cover glass62lies flush with the upper surfaces of bezel14, giving device10an attractive finished appearance.

If desired, springs114(i.e., spring members such as spring member180) may be used to form a support structure to which components in device10may be mounted. An arrangement of this type is shown inFIG.10. As shown inFIG.10, spring member180may have portions that form a bracket186. Vibrator92(or other suitable components) may be attached to spring member180and device10using bracket186. Bracket186may be formed from a bent portion of member180or may be formed from a separate structure that is attached to member180. Screws such as screws192may be used to connect a mounting bracket such as vibrator mounting bracket190to bent tip portion of bracket186to hold vibrator92in place. An advantage of mounting moving components such as vibrator92to a metal structure such as spring member180is that this type of arrangement may enhance the robustness of device10and may make device10less prone to failure. Arrangements of the type shown inFIG.10may also consume less space within the handheld device than conventional arrangements. As shown inFIG.10, spring member180may have prongs such as prong201. Prong201may form a grounding spring that makes electrical contact between bezel14and the frame of tilt assembly60(e.g., midplate206and vertical midplate members208ofFIG.8).

Spring prongs182(and201) may flex during assembly. Following assembly, spring prongs182may engage clips112on tilt assembly60. As shown inFIG.11, each clip112may have a main elongated member198. Elongated members such as elongated member198may be welded to frame struts168and may extend along the edge of tilt assembly60parallel to longitudinal dimension200. Elongated member198may be substantially planar (as an example) and may have a planar surface aligned with longitudinal dimension200and vertical dimension202. Portions194of elongated member198may be bent with respect to vertical dimension202and with respect to the planar surface defined by dimensions202and200. Bending portions194inwardly away from the plane of elongated member198angles portions194so that bent portions194are angled with respect to vertical dimension202. This forms holes196that can receive protruding spring prongs182(FIGS.9and10) when tilt assembly60and housing assembly70are connected to each other. Holes may also be formed by removing portions of elongated member198, by bending or otherwise manipulating portions of member198sideways or in other directions, by bending multiple portions of member198within each hole, etc. The arrangement ofFIG.11in which holes196have been formed by bending portions194down and inwards is merely illustrative.

With one suitable embodiment of tilt assembly60, there is a member such as member198that forms a clip on each side of tilt assembly60. The perspective view ofFIG.11shows an illustrative clip112that has been formed on the right side of tilt assembly60.

As described in connection withFIG.10, because springs114are attached to bezel14and thereby housing12, springs114may be used to form a mounting structure for components such as vibrator92. In particular, a spring such as spring114may be configured to form a mounting bracket186having a horizontal planar member188. During component mounting operations, fasteners such as screws192may be inserted into holes226(FIG.17).

A perspective view of an end of device10is shown inFIG.12. As shown inFIG.12, a bracket-shaped conductor that is mounted to printed circuit board72may have a portion that forms a spring such as spring203. Spring-loaded pin210may be used as a positive signal terminal that forms an electrical connection between a positive radio-frequency signal path in an antenna transmission line structure on board72and a flex circuit antenna resonating element. The transmission line structure may be used to interconnect the antenna resonating element to radio-frequency transceiver circuitry on the printed circuit board.

Dock connector20may have a conductive frame205(e.g., a metal frame), and pins207. Pins207may be electrically connected to corresponding traces in dock connector flex circuit199.

Midplate206may be formed from metal and may form part of tilt assembly60. Structures208(FIG.8) may form vertical portions of midplate206. Midplate206may be used to provide structural support for components such as display16in tilt assembly60. With one suitable arrangement, midplate206may be formed from a conductive material such as metal. Electrical components in device10(e.g., the display, touch screen, etc.) may be grounded to midplate206. Spring201on spring member180of spring114may be used to electrically connect (ground) midplate206(and the components that are grounded to midplate206) to bezel14or other suitable conductive housing structures.

As described in connection withFIG.10, a vibrator such as vibrator92may be mounted in device10. Vibrator92may be used, for example, to alert a user of device10when an incoming telephone call is received.

A conventional vibrator mounting assembly in a handheld device is shown inFIG.13. Conventional vibrator mounting assembly300ofFIG.13has a vibrator306housed within boot308. Boot308is press fit between two legs304. Legs304are attached to housing structure302. Vibrator306, which has electrical connections to device circuitry, vibrates when signaled, such as when a phone call is being received. Boot308is made from an elastomeric material. Because boot308has elasticity, boot308tends to dampen vibrations from vibrator306before these vibrations are conveyed to legs304. This tends to reduce the efficiency of conventional vibrator mounting structures of the type shown inFIG.13. Legs304also consume a relatively large amount of space within the device.

FIG.14illustrates another conventional vibrator mounting arrangement. In theFIG.14arrangement, vibrator402is mounted to a housing using bracket404. Vibrator assembly400has screws406and408that attach bracket404and vibrator402to the housing. Welds may also be used in attaching vibrator402. Assemblies such as assembly400ofFIG.14tend to consume large amounts of horizontal space, as indicated by arrow410.

FIG.15is a schematic view of a vibrator mounting assembly in accordance with an embodiment of the present invention. Arrangements of the type shown inFIG.15may consume less space than conventional arrangements. Assembly500may receive structural support from housing12and bezel14. Vibrator92may have a motor that spins a weight around vibrator axis504. The weight is typically off the center of axis504, so that vibrator92vibrates.

Vibrator92may rest in a cavity such as vibrator cavity508on an elastomeric support such as biasing member506. Member506may help bias vibrator92upwards against bracket190. Mounting bracket190may bias vibrator92downwards in the general direction of arrow503. Mounting bracket190may be attached to housing12using any suitable technique. For example, hook512of bracket190may engage portion510of housing12through a slot or other hole520. Screws such as screw192may hold down bracket190at its other end511. A screw receiving member such as threaded metal insert516may receive screw192through holes505in bracket190and portions188of spring114. Metal insert516may be welded to horizontal portions188of spring member180at weld points such as weld points513. Spring member180may be connected to bezel14by welds (e.g., welds at points such as weld points515). Inserts such as insert516may include threaded holes into which screws192may be screwed during assembly.

A perspective view of a portion of device10in the vicinity of vibrator92is shown inFIG.16. As shown inFIG.16, vibrator92may be mounted beneath mounting bracket190. One end of bracket190may have hooks512that pass through holes520in housing12and engage the undersides of housing portions510. Bracket portions511at the other end of bracket190may be secured by screws192. Vibrator92may have a motor such a motor522that spins a weight such as weight526about axis523. Weight526may be mounted off center, so that vibrations are crated as weight526spins about axis504.

Spring114may have spring prongs182that mate with the clips on tilt assembly60. Spring member180of spring114may have a bend such as bend530that forms horizontal support bracket portions188of spring114. Support bracket portions188may support vibrator mounting bracket190. Electrical contacts such as springs524may be used to make electrical contact between the power leads of vibrator92and control circuitry (e.g., pads on an overlapping circuit board).

Springs such as spring114ofFIG.16may be attached to bezel14(e.g., by welds). Bezel14may, in turn, be attached to housing12(e.g., using a plastic overmolding process, using screws or other fasteners, using adhesive, using a combination of these attachment techniques, etc.). Portion188of spring114may therefore form a horizontal mounting structure that helps attach vibrator92to housing structure12. If desired, other electrical components (e.g., a camera, speaker, microphone, etc.) may be attached using one or more brackets such as bracket190and bracket portion188. The use of bracket190and portion188of spring114to attach vibrator92to housing12is merely illustrative.

FIG.17is a perspective view of device10in the vicinity of spring member portion188. TheFIG.17view is similar to the view ofFIG.16, but vibrator92is not present so that threaded holes226of metal inserts516and holes505in portions188are not obscured by vibrator92. During component mounting operations, fasteners such as screws192ofFIG.15may be screwed into holes226.

If desired, vibrator92may be mounted using a bracket that is not directly connected to springs114. This type of arrangement is shown in the cross-sectional view ofFIG.18. As shown inFIG.18, in vibrator mounting assembly800, vibrator92may be mounted to housing804(e.g., housing12ofFIG.1) using bracket802. Bracket802may bias vibrator92downwards towards elastomeric support810. Elastomeric support810may bias vibrator92upwards towards bracket802. Bracket802may have one end812that engages hole814in housing804and another end803that is held in place by screws such as screw806. Screws such as screw806may be screwed into threaded metal inserts such as threaded metal insert808. Metal insert808may be connected to housing804(e.g., using fasteners, a press fit, adhesive, an overmolding process, etc.).

Screws such as screw806and192may, if desired, be omitted. An illustrative vibrator mounting arrangement in which the bracket mounting screws have been omitted is shown inFIG.19. As shown inFIG.19, bracket904of mounting structures900may have a portion908that biases vibrator92downwards towards elastomeric support907on device housing903. Elastomeric support907may bias vibrator92upwards towards portion908of bracket904. Bracket904may have an end portion such as end909that engages a hole such as hole911in housing903. Housing903may be connected to bezel902(e.g., a conductive bezel formed from metal or other suitable materials). Bracket904may be connected to bezel902without using screws (as an example). With one suitable arrangement, portion910of bracket904may be welded or otherwise attached to bezel902.

If desired, welds may be formed between vibrator92and mounting brackets in device10. For example, portion908of bracket904may be welded to vibrator92at weld location906. Elastomeric biasing members such as biasing member907(FIG.19),810(FIG.18), and506(FIG.15) may be omitted or biasing members for vibrator92may be formed using other device structures. For example, biasing members for vibrator92may be formed from coil springs, leaf springs, bent metal structures (e.g., bent brackets), etc.

The process of assembly device10from numerous components may be complex. Accordingly, it may be desirable to form device10from multiple subassemblies. As an example, device10may be formed from tilt assembly60and housing assembly70. In turn, these assemblies may each be formed from one or more subassemblies.

As an example, a subassembly may be formed using a speaker enclosure or other internal support structure. Components that may be mounted to this type of assembly include a speaker (e.g., a speaker such as speaker78ofFIG.3for port22that is housed within the speaker enclosure), a microphone such as microphone76, a dock connector such as dock connector20, and an antenna (e.g., a flex circuit antenna containing one or more conductive antenna resonating element traces). An assembly of this type, which may sometimes be referred to as an acoustic module, may be manufactured as a separate stand-alone portion of device10, thereby facilitating testing and enhancing manufacturability.

An exploded perspective view of an illustrative acoustic module is shown inFIG.20. As shown inFIG.20, acoustic module119may include a speaker enclosure such as speaker enclosure118. Speaker enclosure118may be formed from one or more molded plastic parts (as an example). Speaker enclosure118may be substantially sealed except for an opening for port22. Speaker78(FIG.3) may be mounted within speaker enclosure118(in the region under dashed lines117), so that one side of the speaker faces port22and the other side of the speaker faces the sealed hollow interior of enclosure118. In this type of configuration, speaker enclosure118may serve as a closed speaker box that improves speaker performance.

As shown inFIG.20, components such as microphone76, antenna flex circuit147, and dock connector20(and associated dock connector flex circuit199and circuit components on flex circuit199) may be mounted on speaker enclosure118. In this capacity, speaker enclosure118may serve as a unifying assembly for multiple parts of device10.

If desired, a mesh cover148(e.g., metal mesh) may be placed over opening22. If desired, a layer of acoustic mesh may be placed behind mesh148. Mesh146(e.g., a metal mesh) may be used to cover microphone76. If desired, a layer of acoustic mesh may be placed behind mesh146. The acoustic mesh may be formed from a plastic mesh material that has smaller mesh openings than the metal mesh (as an example).

Microphone76may have an associated support structure152(sometimes referred to as a “boot”). Structure152may be formed of any suitable material. With one suitable arrangement, structure152is formed from an elastomeric material such as silicone. This allows structure152to form good environmental seals with enclosure118and other portions of device10.

During assembly, microphone boot152may be mounted in a mating hole such as hole144within speaker enclosure118. Hole144may have features that engage boot152and that help to form seals between boot152and enclosure118. These seals and associated seals formed between boot152and the walls of housing12may help prevent intrusion of moisture or particles into the interior of device10. Region158of boot152may have one or more sealing features such as raised ribs. These sealing features may help to enhance the quality of the seal formed between boot152and housing12. One or more holes such as hole156may be used to allow sound to enter microphone76. Flex circuit154may be used to interconnect microphone76with circuitry in device10.

Antenna structure147may be formed from a layer of flex circuit (e.g., a flexible circuit substrate formed from polyimide or other suitable flexible dielectric). The flex circuit layer may include one or more conductive antenna resonating element traces (e.g., traces of copper or other suitable conductor suitable for forming an antenna). The underside of enclosure118may have a planar surface or a surface with one or more non-planar features. As an example, the underside of enclosure118may have a generally planar surface with slightly curved edges to conform to a comparably shaped housing12. Antenna resonating element flex circuit147may be connected to the underside of enclosure118using adhesive (e.g., double-sided adhesive film), or other suitable attachment mechanisms. In this type of arrangement, enclosure118forms a support structure for antenna resonating element flex circuit147that helps to define the shape of the antenna for device10and that helps to locate the antenna structure within device10. If desired, antenna flex circuit147may have alignment features such as hole149that mate with corresponding pegs or other alignment features on the underside of enclosure118.

Dock connector20may be mounted to enclosure118on ledge portion121of enclosure118. Ledge portion121may be formed from a recess of any suitable shape. In the example ofFIG.20, recess has a shape with vertical and horizontal sides. This is, however, merely illustrative.

Any suitable attachment mechanism may be used to secure dock connector20to enclosure118(e.g., adhesive, fasteners, alignment features, etc.). Dock connector flex circuit199may be rigidly attached to dock connector20. For example, adhesive on the underside of dock connector flex circuit199may be used to connect dock connector flex circuit199to enclosure118. This may help to attach dock connector20to enclosure118. If desired, dock connector20may have alignment posts such a posts127that mate with matching alignment holes129on speaker enclosure118. Inserting posts127into holes129may also help to attach dock connector20to enclosure118. During assembly, acoustic module119may be attached to other portions of device10(e.g., housing assembly70) using screws that pass through dock connector holes such as holes123in dock connector frame member205. Enclosure118may also have features such as slot125that may be used when mounting acoustic module119within device10.

FIG.21shows a finished acoustic module119to which dock connector20, microphone76, and antenna resonating element147have been mounted. A speaker for speaker port22may be mounted to the inside of closed box speaker enclosure118(e.g., under the region defined by dashed lines117). Solder terminals131may be used to make electrical connection to the speaker within speaker enclosure118. Antenna flex circuit147may have a ground clip such as ground spring145that is used in grounding the antenna resonating element traces within flex circuit147.

If desired, additional components may be mounted to speaker enclosure118to form a subassembly for device10that contains more parts or fewer components may be mounted to speaker enclosure118to form a subassembly for device10that contains fewer parts. Different components may also be attached to speaker enclosure118(in additional to or instead of the illustrative components ofFIGS.20and21).

The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.