PATENT DOCUMENT

Publication Number: US-8385060-B2
Application Number: US-55138409-A
Country: US
Kind Code: B2

Title: Handheld computing device

Abstract:
A handheld computing device is disclosed. The handheld computing device includes a seamless housing formed from an extruded tube. The extruded tube includes open ends and internal rails which serve as a guide for slidably assembling an operational assembly through the open ends of the extruded tube, a reference surface for positioning the operational assembly relative to an access opening in the seamless housing, and a support structure for supporting the operational assembly during use.

Claims:
1. A method of assembling a portable electronic device, comprising:
 providing a seamless housing, the seamless housing comprising at least a first open end and a resilient reference structure formed on an inside surface of the housing; 
 inserting a pre-tested device module into the first open end using the resilient reference structure as a guide, the device module including a display assembly and a main logic board (MLB) assembly, wherein the display assembly is fixed to a frame and wherein the MLB assembly is moveably mounted to the frame such that the MLB assembly can move relative to the display assembly; 
 affixing the location of the display assembly to a reference point on the seamless housing with a cover glass, thereby locking the device module into place; 
 coupling the display assembly to the MLB assembly using a cross over flex, the cross over flex comprising a first connector, a second connector and a flexible body electrically coupling the first connector and the second connector, the flexible body allowing the second connector to rotate and translate with respect to the first connector, the coupling comprising:
 connecting the first connector to the display assembly, 
 rotating and translating the second connector with respect to the first connector and, 
 connecting the second connector to the MLB assembly; and 
 
 positioning the MLB assembly in relation to the fixed display assembly. 
 
     
     
       2. The method as recited in  claim 1 , comprising:
 electrically connecting a pre-tested user interface module to the device module; and 
 locking the user interface module into place using an end cap having a locking tab. 
 
     
     
       3. The method as recited in  claim 2 , wherein the seamless housing includes a display opening. 
     
     
       4. The method as recited in  claim 3 , wherein the locking the device module into place comprises:
 centering the display assembly in the display opening; 
 placing the cover glass within the display opening, the cover glass having a locking mechanism, the locking mechanism configured to interact with the housing at the display opening to lock the cover glass in place; 
 pressing on the cover glass to engage the locking mechanism, wherein the pressing forces the display assembly to compress and engage the resilient reference structure. 
 
     
     
       5. The method as recited in  claim 1 , wherein the portable electronic device includes a camera module. 
     
     
       6. The method as recited in  claim 5 , further comprising:
 aligning the camera module to the housing a camera alignment pin, the camera alignment pin having a head portion and a pin portion. 
 
     
     
       7. The method as recited in  claim 6 , wherein the aligning using the camera alignment pin comprises:
 inserting the camera alignment pin portion through a pin hole in a rear portion of the housing, wherein the pin hole is shaped in accordance with the shape of the camera alignment head portion; 
 inserting the pin portion through a camera alignment hole in the camera module; and 
 inserting the camera alignment pin portion into a camera alignment hole, wherein the camera alignment hole is formed from a front portion of the housing such that the alignment pin portion is anchored in the camera alignment hole and the camera alignment head portion is fitted into the pin hole in the rear portion of the housing such that the camera module is supported by the front and rear portions of the housing. 
 
     
     
       8. The method as recited in  claim 5 , further comprising:
 a camera boot, wherein the camera boot includes a plurality of grooves, the plurality of grooves used to form a dust seal slideably formed with the housing. 
 
     
     
       9. A portable electronic device, comprising:
 a housing; 
 a main logic board, (MLB) assembly including a board-to-board connector for coupling to a flex connector, wherein the MLB is positioned within the housing; and 
 a integrated flex connector adapted for electrically connecting each of a plurality of components to the board to board connector on the MLB, the components arranged in at least two dimensions comprising:
 a single electrical board to board connector, 
 a hold switch connector coupled to the board to board connector through a service loop, wherein the service loop accommodates positional adjustments between a hold switch disposed on the housing and the integrated flex connector; 
 a first portion having a first connector electrically connected to the single electrical board to board connector, 
 a second portion independent of the first portion, the second portion having a second connector electrically connected to the single electrical board to board connector, and 
 a third portion independent of the first portion and the second portion, the third portion having a third connector electrically connected to the single electrical connector, wherein the single electrical connector provides an independent electrical path for the each of the first, second, and third connectors to a external circuit wherein the external circuit is a test fixture, configured to test the functionality each of the first, the second and the third components independently, wherein a first component connected to the first connector is a microphone, a second component connected to the second connector is an audio module, and a third component connected to the third connector is a piezo-acoustic module. 
 
 
     
     
       10. The portable electronic device as recited in  claim 9 , wherein the first component connected to the first connector or the second component connected to the second connector or the third component connected to the third connected can each independently receive power from the external circuit. 
     
     
       11. The portable electronic device as recited in  claim 9 , wherein those of the first, the second, and the third components that fail the function test can be replaced prior to insertion into a portable electronic device. 
     
     
       12. The portable electronic device as recited in  claim 9 , wherein the integrated flex connector electrically connects the microphone, the audio module, and the piezo-acoustic module each independently to the main logic board in the portable electronic device. 
     
     
       13. A portable electronic device, comprising:
 a housing, the housing having a top opening and a side opening; 
 a display assembly, the display assembly comprising a display, the display centered at the top opening and fixed to the housing; 
 a main logic board, (MLB) assembly, wherein prior to attachment of the MLB assembly to the housing during a portable electronic device assembly operation, the MLB assembly floats with respect to the display assembly; and 
 a cross over flex arranged to electrically connect the display assembly and the MLB assembly and provide a mechanism for adjusting a position of the floating MLB assembly with respect to the fixed display assembly, the cross over flex comprising: 
 a first connector, the first connector connected to the display assembly, 
 a second connector, the second connector connected to the MLB assembly, and 
 a fold over body portion, the fold over body portion comprising electrical conductors and having a length sufficient to permit the second connector to rotate and translate with respect to the first connector when connected to the display assembly for adjusting the position of the floating MLB assembly. 
 
     
     
       14. The portable electronic device of  claim 13 , wherein the housing further comprises:
 a cover glass; 
 at least two grooves arranged on an inner surface of the housing; and 
 rails arranged to fit into the grooves and form an internal reference structure wherein the internal reference structure cooperates with the display assembly and the cover glass to force the cover glass against the housing and position an upper surface of the cover glass flush with an outer surface of the housing. 
 
     
     
       15. The portable electronic device of  claim 14 , wherein the housing is formed of metallic or plastic material. 
     
     
       16. The portable electronic device of  claim 13 , further comprising an end cap configured to seal the side opening, wherein the end cap shaped to conform to a internal cross section of the housing.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to portable computing devices. More particularly, the present invention relates to enclosures of portable computing devices and methods of assembling portable computing devices. 
     2. Description of the Related Art 
     In recent years, portable computing devices such as laptops, PDAs, media players, cellular phones, etc., have become small, light and powerful. One factor contributing to this reduction in size can be attributed to the manufacturer&#39;s ability to fabricate various components of these devices in smaller and smaller sizes while in most cases increasing the power and or operating speed of such components. Unfortunately, the trend of smaller, lighter and powerful presents a continuing design challenge in the design of some components of the portable computing devices. 
     Conventional assembly techniques teach placing the operational components within the enclosure sections at a time after which they are electrically connected. However, even though the individual component can be pre-tested prior to assembly, there is no way to pre-test the assembled components. The only testing that can occur takes place either during the assembly process or immediately after the assembly process is complete. If there is a fault discovered, or the device fails to meet outgoing functional quality requirements, the entire device is either scrapped or dis-assembled in order to find and correct the defective component thereby greatly reducing efficiency and increasing costs. 
     In view of the foregoing, there is a need for improved component density and associated assembly techniques that reduce cost and improve outgoing quality. In addition, there is a need for improvements in the manner in which small, handheld devices are assembled. For example, improvements that enable structures to be quickly and easily installed within the enclosure, and that help position and support the structures in the enclosure. It is also desirable to minimizing the Z height of the assembled components in order to reduce the overall thickness of the portable computing device and thereby improve the overall aesthetic look and feel of the product. 
     SUMMARY OF THE INVENTION 
     A portable electronic device is disclosed. The portable electronic device includes at least a frame and a device module mounted to the frame. The device module includes a first function assembly, a second function assembly, and an electrical interface configured to facilitate communication between the first and the second function assemblies. The first and the second function assemblies are movable relative to one another. The electrical interface can expand or contract commensurate with the relative displacement between the first and the second assemblies. The portable electronic device also includes a user interface module electrically coupled to the device module. The device module and the user interface module are each stand alone modules in that each can be fully function tested prior to being incorporated into the portable electronic device. 
     A method of assembling a portable electronic device is disclosed. The method can be carried out by performing at least the following operations. Providing a seamless housing, the seamless housing having at least a first open end and a reference structure formed on an inside surface of the housing, inserting a pre-tested device module into the first open end using a resilient reference structure as a guide. The device module includes a first function assembly and a second function assembly the first function assembly being fixed to the frame and the second function assembly being moveably mounted to the frame such that the second function assembly can move relative to the first function assembly. Next, affixing the location of the first function assembly to an reference point on the seamless housing and moving the second function assembly in relation to the fixed first function assembly. 
     A user interface module for use in a portable electronic device is disclosed. the user interface module including at least a user touch interface having a plurality of discrete regions sensitive to a user&#39;s touch, a plurality of actuators each being responsive to a user touch event at a corresponding one of the plurality of touch sensitive regions, a flexible electrical connector configured to electrically connect the plurality of actuators to a connector, and a diffusion bonded support plate formed of a number of chemically etched layers, the support place providing support to the user interface assembly, wherein the user interface module is fully pre-tested prior to installation in the portable electronic device. 
     An integrated connector adapted for electrically connecting each of a plurality of components to an external circuit independent of one another where the components arranged in at least two dimensions is disclosed. The integrated flex connector including at least a single electrical board to board connector, a first portion having a first connector electrically connected to the single electrical board to board connector, a second portion independent of the first portion, the second portion having a second connector electrically connected to the single electrical board to board connector, and a third portion independent of the first portion and the second portion, the third portion having a third connector electrically connected to the single electrical connector, wherein the single electrical connector provides an independent electrical path for the each of the first, second, and third connectors to the external circuit. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention 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  shows a generic block diagram a modular portable electronic device in accordance with the described embodiments. 
         FIG. 1B  is a perspective diagram of an embodiment of a handheld computing device. 
         FIG. 2  shows an exploded view of portable electronic device shown in  FIG. 1  illustrating the juxtaposition of various electrical and structural components described in more detail below. 
         FIG. 3  is a perspective diagram of an embodiment of seamless housing used to form the handheld computing device shown in  FIG. 1 . 
         FIG. 4  shows various views of click wheel assembly. The views include an exploded view and a reverse view of click wheel flex showing reverse dome buttons in accordance with the described embodiments. 
         FIG. 5  shows a front and rear view of m-frame assembly in accordance with the described embodiments. 
         FIG. 6  shows an embodiment of metal frame used in the fabrication of m-frame assembly of  FIG. 5 . 
         FIG. 7  shows an embodiment of display device showing a cross over flex in a folded state and an extended, or open, state. 
         FIGS. 8A-8C  shows an embodiment of camera module and camera boot. 
         FIG. 9  shows an embodiment of I/O flex. 
         FIG. 10  shows a top and bottom view of audio module in accordance with the described embodiments. 
         FIG. 11  shows a representation of cover glass assembly and display device in relation to metal frame in accordance with the described embodiments. 
         FIGS. 12-14  shows a flowchart detailing a process for manufacturing a portable electronic device in accordance with the embodiments described herein. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention generally pertains to portable computing devices and more particularly to components of and methods for assembling portable computing devices. One aspect of the invention relates to a seamless housing formed of a material such as plastic or metal such as aluminum. The seamless housing can be formed via an extrusion process. The metallic nature of the seamless housing can provide superior wear properties as well as provide superior impact protection for internal components in addition to provide an electrical grounding plane. In addition to providing superior wear and protection, the metal used to form the seamless housing can be worked to provide a more aesthetically pleasing appearance thereby improving the overall user experience. For example, the sheen and luster of aluminum can be used to provide an aesthetically pleasing appearance to the portable computing device. 
     The seamless housing can also include at least one open end, a window to receive a display device, and an opening to receive a user input device, such as a touch sensitive click wheel. The open end can be sized for slideably receiving a m-frame assembly, also referred to as a sled, formed of a number of operational components mounted to a metal frame. The metal frame can be used as a metal support on which a number of operational components can be mounted at a fixed position on the metal frame. Other components, however, can be mounted on the metal frame and yet still be moved relative to the fixed components. In this way, an assembly operator can easily align those components that must be placed in specific locations (such as the audio jack and connector being flush to the bottom of the housing) while the other components remain fixed. The operational components mounted to a fixed position on the metal frame can include a display device since it is critical that the display device remain centered in the display window. Components that can be mounted and yet still be moved in relation to the display device can include a main logic board also referred to as a printed circuit board (PCB). The PCB can act as a transport vehicle for components attached thereto such as a microprocessor, a microphone, a camera, a data port having a connector, a piezo-electric audio transducer, and an audio jack. In the case of the audio jack, the ability to move the PCB in relation to the display enables an assembly operator to move the audio jack flush to the bottom of the portable electronic device while still maintain the proper centering of the display. 
     In order to increase density of components mounted to the metal frame, the number of board to board interconnects, the pitch between interconnects, and the amount of board real estate used for interconnects can be optimized. This optimization can be carried out in a number of ways. For example, using surface mount and soldering whenever possible provides for reduced use of board real estate and better electrical connections than would otherwise be used if a conventional connector was used. An integrated flex where a number of components are soldered to a single flex structure having a single board to board connector is one approach that takes advantage of both surface mount, soldering, and reduced number of connectors. A stiffener plate can be used to disperse stress on the flex at a connection. The stiffener plate can be metal and also used to provide a ground connection. 
     The single integrated flex can be used to connect a plurality of different operational components. The single integrated flex can include a single board to board interconnect suitable for providing an electrical connection between the plurality of operational components and a substrate or printed circuit board (PCB). The plurality of operational components connected by way of the single integrated flex can include the audio jack and associated circuitry, the microphone, a hold switch, and the piezo-electric audio transducer. The singly integrated flex allows for pre-assembly testing of the components attached thereto simply by connecting the single board to board connector to a test fixture. 
     Another approach that can taken to facilitate assembly and thereby improve assembly throughput is by providing novel techniques for mounting components onto the metal frame. One such technique is referred to as “book” mounting whereby the metal frame is structured to accommodate the placement of a component on one side of the metal frame. The assembly operator can then lower the component as if closing a book onto the other side of the metal frame where a snap attachment feature can be used to secure the component. Using this technique, the assembly of small components onto the metal frame is easy and less time consuming than conventional approaches to mounting components. 
     Typically, the m-frame assembly is formed in a pre-insertion assembly operation separate from the assembly process that is used to manufacture the portable computing device. One of the advantages of pre-assembling the m-frame assembly is that once assembled, the m-frame assembly can be functionally tested prior to being inserted into the housing. In this way, only those m-frame assemblies that have been determined to pass functional testing are used in the manufacture of the portable computing device thereby greatly improving assembly outgoing quality. Moreover, by being able to pre-test the m-frame assembly, any debugging, tuning, or repair can be performed prior to the actual insertion of the m-frame assembly into the seamless housing. 
     In addition to the stand alone m-frame assembly, a stand alone touch sensitive user input device, such as a click or touch wheel, can be assembled and tested separately from the m-frame assembly. Similar to the m-frame assembly, the stand alone user input device can be functionally tested prior to assembly into the portable computing device. In this way an inventory of pre-tested stand alone m-frame subassemblies and stand alone click wheel assemblies can be created and called upon as needed in, for example, a just in time (JIT) type assembly operation. Furthermore, the modularity of the stand alone m-frame assembly and click wheel assembly affords the opportunity to easily repair a defective portable computing device by merely replacing the defective click wheel assembly or m-frame assembly without the need to debug and repair in situ as is conventionally the case. 
     The click wheel assembly can include a number of components such as a click wheel faceplate having a number of button function icons and a center button. A number of dome buttons corresponding to the button function icons are connected to a flex structure separate from a flex structure on which dome button corresponding to the center button is mounted. In the described embodiment, in order to reduce Z height, the dome buttons are mounted in a reverse orientation. Furthermore, by mounting the dome button associated with the center button on a separate flex structure than that used for the dome buttons corresponding to the center button, less material can be used. Additionally, all of the reverse mounted dome buttons are mounted to the same side of their respective flex structures. In this way, the dome button/flex structures can be fabricated in a single set up. 
     Once the m-frame assembly has been properly inserted and the display centered and locked in place, the stand alone click wheel assembly can be electrically connected and placed within the click wheel opening in the housing. The click wheel assembly can grounded to a chassis ground (i.e., metal housing) by way of a metallic coil spring included in a hole formed in a click wheel support structure. The metallic spring can provide both a path to ground (i.e., the metallic housing) and resilient support for the click wheel assembly. 
     A resilient reference structure on an interior surface of the seamless housing can be used as a guide during assembly. The resilient nature of the reference structure can be provided by resilient material, such as plastic, attached to a bottom surface of the seamless housing. During assembly, the m-frame assembly can be placed within the open end of the seamless housing. A display device chassis (usually formed of plastic) can be placed in contact with the resilient material of the guide. The m-frame assembly can then be slideably inserted into the seamless housing where the display device chassis rides along the resilient guide. The m-frame assembly is inserted until an active area of the display device is centered with respect to a black mask within a display window formed in the seamless housing. Once the display device is centered, a protective cover glass having a locking feature such as a flange can be placed on the display and locked into place. The locking in place of the protective cover can also have the effect of restraining the m-frame assembly in XY. Furthermore, the protective cover glass can also assert a force onto the display device chassis that can be opposed by the resilient guides onto which the display device rests. This opposing force can have the effect of forcing the display device/protective glass up against the housing thereby assuring that the protective glass is substantially flush with the housing. 
     As described above, in order to properly align the various components within the seamless housing after the display device is centered and fixed in place, the assembly operator is provided the opportunity to move other components relative to the display device. However, in order to facilitate this movement, the display device has what is referred to as a cross over flex that provides a modicum of additional length of flex used to accommodate the necessary movement of the other components relative to the display device. Moreover, this cross over feature allows for greater allowance for the placement of a corresponding connector on the PCB. 
     These and other embodiments of the invention are discussed below with reference to  FIGS. 1-14 . 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  illustrates portable electronic device  1  in accordance with the described embodiments. Device  1  can be configured as any of a number of electronic devices such as a portable media player, cell phone, smart phone, etc. In the described embodiment, portable electronic device  1  can be modular in nature. By modular it is meant that device  1  can be formed of modules each containing a plurality of functional assemblies. This modularity can also facilitate efficient and cost effective modular assembly practices described below. In the described embodiments, the modules can be stand alone modules in that each module can be tested and confirmed as being fully functional prior to being incorporated into device  1 . In this way, only fully tested and fully operational modules can be used in the assembly of device  1  thereby substantially improving assembly yield. Modules, in turn, can include a plurality of functional assemblies. The functional assemblies can include components arranged to perform specific functions. For example, a camera assembly can include a camera configured to provide both still and video to a processor assembly. 
     Device  1  can include frame  2  that can be used to provide mechanical support for device module  3 . Device module  3  can, in turn, include a number of functional assemblies such as assembly  4  connected to assembly  5  by way of interface  6 . In the described embodiments, device module  3  can be a stand alone module having a number of functional assemblies that can be tested prior to assembly into the device  1 . Being stand alone, module  3  can be connected to an external circuit such as a tester configured for functional testing. Typically, the tester has an on board power supply arranged to supply a pre-determined supply voltage to the circuit under test (i.e., module  3 ). As a result of the testing, any assemblies found to be either malfunctioning or not operating according to spec can either be repaired or replaced. In this way, an inventory of pre-tested device modules can be stored and made ready for assembly of electronic device  1 . 
     Device  1  can be assembled in a labor and cost effective manner by taking advantage of the modularity inherent in the design of device  1 . Frame  2  can be used as a transport mechanism (along the lines of a sled used to transport objects laid thereon) as well as a supporting structure. Since module  3  is mounted to frame  2 , frame  2  can be used to transport module  3  into housing  7  in one operation avoiding the cost in time and labor of in situ component assembly. Since module  3  has been fully tested and confirmed operational prior to assembly, there is a high probability of continued operability after the insertion procedure. However, even in those rare instances where an inserted module is found to be defective, the defective module can be easily swapped for another functioning module. In this way, there is no need for time consuming failure analysis. Device  1  also includes a separate user interface module  8  that, like device module  3 , can be fully function tested prior to being electrically coupled to device module  3  and incorporated into device  1 . 
     The described embodiment can provide a number of features that facilitate the assembly of device  1 . For example, assembly  4  and/or assembly  5  can be mobile with respect to housing  7  and/or each other. In some cases it may be necessary to affix assembly  4  to a specific position relative to an external reference (such as an opening in housing  7 , for example). One such example can be if assembly  4  includes a display device, the display device must be precisely centered within an opening in housing  7 . Therefore, once the display is centered, the position of assembly  4  is fixed and cannot move relative to housing  7 . However, even though assembly  4  must remain fixed, assembly  5  may have to be aligned with respect to housing  7  at a position inconsistent with the current relative position of assembly  4 . Therefore, frame  2  can include an intra-frame transport mechanism on which assembly  5  can be mounted. The intra-frame transport mechanism can allow assembly  5  to move relative to assembly  4 . In order to accommodate any movement between assembly  4  and assembly  5 , interface  6  can be expand (or contract) commensurate with the relative displacement between assembly  5  and assembly  4 . 
       FIG. 1B  illustrates a specific embodiment of modular portable electronic device  1  shown in  FIG. 1A . More specifically,  FIG. 1B  shows a front and rear view of fully assembled handheld portable electronic device  10 . Portable electronic device  10  can process data and more particularly media data such as audio, video, images, etc. By way of example, portable electronic device  10  can generally correspond to a music player, game player, video player, camera, cell phone, personal digital assistant (PDA), and/or the like. With regards to being handheld, portable electronic device  10  can be operated solely by the user&#39;s hand(s), i.e., no reference surface such as a desktop is needed. In some cases, portable electronic device  10  can be 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 (e.g., the user is not limited by carrying a large, bulky and heavy device). By way of example, the portable electronic device  10  can correspond to consumer electronic products such as computers, media players, personal digital assistants (PDA), telecommunication devices (phone), personal e-mail or messaging devices and/or the like. In one example, the electronic device can correspond to an iPod Nano™ available by Apple Inc. of Cupertino, Calif. 
     Portable electronic device  10  can include housing  100  configured to at least partially enclose any suitable number of components associated with the electronic portable electronic device  10 . For example, housing  100  can enclose and support internally various electrical components (including integrated circuit chips and other circuitry) to provide computing operations for the device. The integrated circuit chips and other circuitry can include a microprocessor, memory, a battery, a circuit board, I/O, various input/output (I/O) support circuitry and the like. Although not shown in this figure, housing  100  can define a cavity, or lumen, into which various mounted components can be inserted. In the described embodiment, at least one fully tested stand alone assembly having various operational components mounted thereon can be inserted into an open end of housing  100 . Once properly positioned and fixed in place, a stand alone and fully tested user interface can be electrically connected to the stand alone assembly and placed within a user interface opening in housing  100 . The user interface can then be locked in place using one of two endplates that are placed on both of the open ends of housing  100 . In this way, the endplates serve to seal the operating components inside housing  100  preventing dust and other environmental contaminants from entering. Cosmetic caps can be placed over the endplates to improve the overall aesthetics of portable electronic device  10 . 
     In addition to providing support and prevention of environmental contamination from damaging the internal components, housing  100  can define at least in part the outward appearance of portable electronic device  10 . That is, the shape and form of the housing  100  can help define the overall shape and form of the portable electronic device  10  or the contour of the housing  100  can embody the outward physical appearance of the portable electronic device  10 . Any suitable shape can be used. In some embodiments, the size and shape of the housing  100  can be dimensioned to fit comfortably within a user&#39;s hand. In some embodiments, the shape includes a slightly curved back surface and highly curved side surfaces. The shape will be described in greater detail below. Housing  100  can be integrally formed in such as way as to constitute is a single complete unit. By being integrally formed, the housing  100  has a seamless appearance unlike conventional housings that include two parts that are fastened together thereby forming a reveal, a seam there between. That is, unlike conventional housings, the housing  100  does not include any breaks thereby making it stronger and more aesthetically pleasing. 
     As seen on the front view, portable electronic device  10  can include display  104 . Display  104  can be fixedly mounted onto a supporting metal frame using a fixing agent such as adhesive that can also act as a dust shield. Display  104  can be used to display images such as video, still images, a graphical user interface (GUI) as well as other information to the user (e.g., text, objects, graphics). By way of example, display  104  can be a liquid crystal display (LCD). When portable electronic device  10  is being assembled, the frame on which display  104  is mounted can be inserted into housing  100  using one of the open ends of housing  100  until display  104  is centered within display window opening  106 . Protective layer  108  can be positioned within opening  106  in front of the display  104  in order to protect display  104  from damage. Protective layer  108  can be formed from any of a number of clear materials such as clear polycarbonate plastic, glass, etc. In the described embodiment, protective layer  108  can include a locking feature (such as a flange). When protective layer  108  is placed over display  104  within the display window opening  106 , the locking feature can be mated with housing  100  thereby applying pressure to display  104 . The applied pressure has the effect of locking into position the various internal components (such as a main logic board, or MLB) mounted to the supporting metal frame on which display  104  is also mounted. 
     Portable electronic device  10  can also include one or more input devices configured to facilitate a transfer of data from the outside world into the portable electronic device  10  and vice versa typically at the behest of a user. The one or more input devices can be used to perform tracking/scrolling or to make selections or to facilitate a user issuing commands to portable electronic device  10 . By way of example, the one or more input devices can correspond to keypads, joysticks, touch screens, touch pads, track balls, wheels, buttons, switches, and/or the like. In the described embodiment, the one or more input devices can include a touch sensitive input device that can take the form of click wheel user interface  110  (being the visible portion of click wheel assembly described in detail below). Click wheel user interface  110  can include at least an annular click wheel  112 . Annular click wheel  112  can be formed of resilient material such as plastic on which are present a number of icons  114  each corresponding to a particular button function that can be performed by portable electronic device  10  in response to a user touch event. By way of example, where portable electronic device  10  is a music player, the button functions can be associated with opening a menu, playing a song, fast forwarding a song, seeking through a menu and the like. In most cases, the button functions are implemented via a mechanical clicking action although they can also be associated with touch sensing. 
     In order to convert the user touch event to a signal that can be processed and acted upon by portable electronic device  10 , each icon  114  can be associated with a corresponding touch sensitive region in the form of click wheel button  116 . In order to reduce Z height of click wheel user interface  110  and help to make it flush with the surface of housing  100 , click wheel button  116  can take the form of a reversed orientation clickable dome button (also referred to as a reverse dome button). By reverse orientation it is meant that the dome portion of click wheel button  116  is oriented to face down towards the interior of portable electronic device  10  as opposed to facing up away from housing  100  in conventional arrangements. Although not shown, each click wheel button  116  is associated with a sensor arrangement. The sensor arrangement can include a plurality of sensors that are configured to activate as the finger passes over or presses on them. In the simplest case, an electrical signal is produced each time the finger passes or presses a sensor. The number of signals in a given time frame can indicate location, direction, speed and acceleration of the finger on the touch pad, i.e., the more signals, the more the user moved his or her finger. In most cases, the signals are monitored by an electronic interface that converts the number, combination and frequency of the signals into location, direction, speed and acceleration information. This information can then be used by portable electronic device  10  to perform the desired control function. 
     Click wheel user interface  110  can also include center button  118  associated with touch sensitive region  120 . When a user presses center button  118 , for example, touch sensitive region  120  can generate a signal that can cause portable electronic device  10  to act in a pre-determined manner. For example, when a user presses center button  118  at the same time that a list of media items are presented on display  104 , touch sensitive region  120  can provide a signal to processing circuitry that can cause a particular one of the listed media items presented on display  104  to be selected. It should be noted that center button  118  can also be configured as a reverse dome button. 
     The position of click wheel user interface  110  relative to seamless housing  100  can be widely varied. For example, click wheel user interface  110  can be placed at any external surface (e.g., top, side, front, or back) of seamless housing  100  that is accessible to a user during manipulation of the portable electronic device  10 . Typically, touch sensitive surfaces of click wheel user interface  110  are completely accessible to the user. For example, click wheel user interface  110  can be located in a lower, front area of seamless housing  100 . Furthermore, click wheel user interface  110  can be recessed below, level with, or extend above the surface of the seamless housing  100 . In the illustrated embodiment, however, the touch sensitive surfaces of click wheel user interface  110  are substantially flush with the external surface of the seamless housing  100 . 
     The shape of click wheel user interface  110  can also be widely varied. For example, click wheel user interface  110  can be circular, rectangular, square, oval, triangular, and the like. Circular shapes, however, allow a user to continuously swirl a finger in a free manner, i.e., the finger can be rotated through 360 degrees of rotation without stopping. Furthermore, the user can rotate his or her finger tangentially from all sides thus giving it more range of finger positions. For example, when the portable electronic device  10  is being held, a left handed user can choose to use one portion of click wheel user interface  110  while a right handed user can choose to use another portion of click wheel user interface  110 . 
     Portable electronic device  10  can also include one or more switches such as power switches, hold switches, and the like accessible through various openings in housing  100 . The power switch is configured to turn the portable electronic device  10  on and off, and hold switch  122  is configured to activate or deactivate click wheel user interface  110 . This is generally done to prevent unwanted commands by click wheel user interface  110 , as for example, when portable electronic device  10  is stored inside a user&#39;s pocket. 
     Portable electronic device  10  can also include one or more connectors for transferring data and/or power to and from portable electronic device  10 . Portable electronic device  10  can include audio jack  124 , data port  126  and in some cases a separate power port for delivering power to the portable electronic device  10 . Audio jack  124  allows audio information to be outputted from portable electronic device  10 . Audio jack  124  can receive an audio post (not shown) that can provide audio signals to external audio rendering devices, such as headphones, speakers, etc. Data port  126  allows data to be transmitted and received to and from a host device such as a general purpose computer (e.g., desktop computer, portable computer). For example, data port  126  can be used to upload or down load audio, video and other image data to and from the portable electronic device  10 . Data port  126  can also be used to download songs and play lists, audio books, e-books, photos, and the like into a storage mechanism included in portable electronic device  10 . In the described embodiment, data port  126  can be any size deemed appropriate such as, for example, a 30 pin connector. As seen by the rear view, portable electronic device  10  can also include a camera module having camera lens  130 , the camera module being configured to provide still or video images. Cosmetic camera trim  132  can provide an aesthetically pleasing finish as well as provide support for camera lens  130 . A microphone can be used to record audible sound passing through microphone hole  134 . In the described embodiment, cosmetic trim  132  can form fit into trim recess  136  formed from housing  100 . Trim recess portion  136  of housing  100  can be formed using a machining process, for example. Although not shown in  FIG. 1B  but described in detail later, trim recess portion  136  can include openings in housing  100  used to provide access to the microphone module, the camera module and an opening used to insert a camera alignment pin. It should be noted that cosmetic trim  132  can obscure the opening used to insert the camera alignment pin since such an opening only need be accessed during the alignment of the camera module. 
     In some cases, the data port  126  can serve as both a data and power port thus replacing the power port. Data port  126  can be widely varied. In one embodiment, the data port  126  is a peripheral bus connector, such as a USB or FIREWIRE connector. These type of connectors include both power and data functionality, thereby allowing both power delivery and data communications to occur between the portable electronic device  10  and the host device when the portable electronic device  10  is connected to the host device. In some cases, the host device can provide power to the media portable electronic device  10  that can be used to operate the portable electronic device  10  and/or charge a battery included therein concurrently with the operating. 
     Although the device can connect through various wired connections, it should be appreciated that this is not a limitation. Portable electronic device  10  can also include a mechanism for wireless communications, as either a transceiver type device or receiver only, such as a radio. For example, as shown, portable electronic device  10  can include an antenna that can be disposed internal to housing  100 . The wireless communications can be based on many different wireless protocols including for example Bluetooth, RF, 802.11, FM, AM, and the like. 
       FIG. 2  shows an exploded view  200  of portable electronic device  10  illustrating the juxtaposition of various electrical and structural components described in more detail below. The relationship and organization of the components within each layer and relationship between layers can be used to facilitate both the assembly and optimization of Z height tolerances of portable electronic device  10 . One aspect of the described embodiments relates to the design of the operational components that facilitate modular assembly of portable electronic device  10 . The modular assembly relates to the fact that portable electronic device  10  is formed of a number of self contained modules. These self contained modules can be powered up and tested and if necessary repaired or tuned prior to being inserted into housing  100 . In this way portable electronic device  10  can be manufactured to be extremely compact, sturdy, aesthetically pleasing and ergonomic at relatively low cost. The pre-assembled and pre-tested modules can include click wheel assembly  400  and metal or m-frame assembly  500  described in more detail below. 
       FIG. 3  is a detailed front and rear view of housing  100 . Housing  100  can take the form of a seamless housing. The seamless nature of the housing  100  provides an aesthetic look and feel to the portable electronic device  10  as well as provides added resistance to deformation and possible damage to internal components caused by the device being dropped. Housing  100  can be formed of extruded aluminum or other materials such as plastic. It should be noted, however, that this configuration is representative in nature only and does not provide limitations constraining the ultimate scope of the invention. The size and shape of seamless housing  100  can be dimensioned to fit comfortably within a user&#39;s hand. In one particular embodiment, seamless housing  100  can be formed from an extruded material such as aluminum or stainless steel thereby providing a seamless look along the length of portable electronic device  10 . That is, unlike conventional seamless housings, seamless housing  100  does not include any breaks between the top and bottom ends thereby making it stronger and more aesthetically pleasing. It should be noted that in those cases where portable electronic device  10  incorporates radio frequency (RF) functionality, such as WiFi, BlueTooth, AM/FM radio, any metals used for construction of seamless housing  100  should possess non-magnetic properties in order to reduce any possibility of interfering with the RF functionalities. Such metals can include, for example, aluminum. 
     In order to help guide at least a portion of the internal components to their desired position within the seamless housing  100  during assembly, housing  100  can include display opening  302  arranged to accommodate display  104  and cover glass  108 . During assembly, an operator can center display  104  to display opening  302 . Housing  100  can also include click wheel assembly opening  304  arranged to receive fully functional click wheel assembly. Flanges  305  can be used to lock the click wheel assembly in the Z direction. Lumen  306  can be sized and dimensioned for receipt of various internal components used in the assembly of portable electronic device  10 . In the described embodiment, an internal reference structure within lumen  306  can include at least two groove structures  308  formed in inner surface  310  of back portion  312  of seamless housing  100 . Grooves  308  can be formed by way of a machining process. Once grooves  308  have been formed, similarly shaped rails formed of plastic or other resilient material can be fitted into grooves  308  and attached to inner surface  310 . In this way, the rails can provide both an assembly reference surface and a supporting structure for pre-assembled components such as a plastic chassis on which display  104  is mounted. 
     Cover glass  108  can be locked into place (i.e., in the XY plane) by bonding cover glass  108  to metal frame using adhesive. Cover glass  108  can be locked into the Z direction using flanges formed on cover glass frame which can then be snapped into housing  100 . Once cover glass  108  is locked into place, the compressive force applied by cover glass  108  onto the metal frame can be transmitted through the metal frame down to the resilient material in grooves  108  upon which the metal frame rests. The resilient material can respond to the compressive force with an opposing force that travels up through the metal frame to cover glass  108 . This opposing force can have the effect of biasing up the metal frame and cover glass  108  (on which cover glass  108  is mounted) thereby forcing cover glass  108  up against housing  100 . In this way, the upper surface of cover glass  108  can be made flush with the upper surface of housing  100  at display opening  302 . 
     In order to maximize the perceived audio output of an integrated speaker assembly used by portable electronic device  10  to broadcast audible sound, a portion of inner surface  310  can be removed to form recess  314 . Recess  314  can be used to form a front acoustic volume associated with a piezo-electric acoustic transducer. It should be noted that as described below, during assembly, a front acoustic volume can be created by forming a sliding seal between an acoustic seal associated with a piezo-electric audio transducer and recess  314 . 
     In order to more easily accommodate the insertion of various internal components within seamless housing  100 , open end  316  (opposite open end  318 ) can receive a self contained unit formed of operational components mounted to a metal frame, or sled. At the conclusion of the assembly process, an end cap having a click wheel locking feature can be used to cover open end  316  and lock click wheel user assembly in place in the XY direction. The end caps are shaped to conform to the internal cross section of housing  100 . In this way, end caps can be inserted into the open ends  316  and  318  such that an outer periphery of the end caps matches an inner periphery of lumen  306 . Furthermore, cosmetic caps can be subsequently placed on the end caps and positioned to be flush with rear surface and front surface of seamless housing  100  thereby providing seamless housing  100  with a substantially uniform appearance. 
       FIG. 4  shows various views of click wheel assembly  400 . The views include an exploded view and a reverse view of click wheel flex showing reverse dome buttons in accordance with the described embodiments. It should be noted that by self contained it is meant that once fully assembled, click wheel assembly  400  is fully functional and capable of being function tested prior to incorporation into portable electronic device  10 . In this way, click wheel assembly  400  can be tested and, if necessary, repaired or tuned, prior to incorporation into portable electronic device  10 . Turning first to the exploded view, click wheel assembly  400  can include a number of structural and electrical components that cooperate to provide a user input device responsive to a touch event be it from a user&#39;s finger, or a stylus, etc. In the described embodiment, the click wheel assembly  400  can include annularly shaped click wheel faceplate  402  and center button plate  404  sized to fit within a central portion of click wheel faceplate  402 . Center button plate  404  can be metallic in nature (for both aesthetic and wear protection reasons) whereas click wheel faceplate  402  can be formed of plastic or other lightweight yet durable material. The choice of metal for center button plate  404  and plastic or plastic like material for click wheel faceplate  402  is based upon the fact that it is contemplated that center button plate  404  will receive substantially greater wear from repeated user touches and presses than will click wheel faceplate  402 . Any disadvantages due to the metallic nature of center button plate  404  (greater weight, higher cost of fabrication, etc.) is more than offset by the anticipated longer useful lifetime of center button plate  404  than would be expected if center button plate  404  had been fabricated with plastic or other such material. In any case, the nature of the material used to form the various buttons can be varied depending on any number of factors in addition to those discussed above. 
     Click wheel faceplate  402  can provide a surface that can cooperate with a number of reverse mounted click wheel dome buttons  406  electrically connected to click wheel flex  408 . The number of placement of dome buttons  406  can be widely varied. In the particular embodiment shown, dome buttons  406  form an array of four buttons circumferentially arranged equidistant from each other on click wheel flex  408 . Click wheel flex  408  can be disposed between click wheel faceplate  402  and click wheel support plate  410 . Center button plate  404  can provide a surface that can cooperate with reverse mounted center dome button  412  that is mounted to center button flex  414  by way of “ears”  415  and electrically connected to click wheel flex  408  by way of single flex connector  416 . Center button plate  404  can also be directly mounted to center button flex  414 . One advantage to using single flex connector  416  and ears  415  is to help reduce the overall height (Z) of click wheel assembly  400 . It should be noted that click wheel dome buttons  406  and center dome button  412  can be located on the same side of click wheel flex  408  and center button flex  414 , respectively, thereby requiring only a single set up to manufacture. In addition, using only flex connector  416  and to connect center button flex  414  and click wheel flex  408 , less material can be used in the manufacture of click wheel assembly  400 . Moreover, the single connection provides for easier placement and rotational alignment of click wheel assembly  400  into housing  100 . 
     Click wheel support plate  410  is used to provide structural support for click wheel assembly  400 . Accordingly, click wheel support plate  410  can be formed from a number of metal plates formed of, for example, stainless steel (such as SUS 304L) that are fusion bonded together at temperatures in the range of 1000° F. The metal plates can be of different thickness. Fusion bonding results in click wheel support plate  410  having a laminated structure that has both strength and a high degree of Z conformity (i.e., very flat). It is this combination of strength and flatness that enables click wheel assembly  400  to present a more uniform touch sensitivity profile across click wheel faceplate  402  and center button plate  404  to the user. It should be noted that prior to the fusion bonding, some of the constituent plates can be chemically etched to form, for example, dome button recesses  416  suitable for receiving dome button shims  418 . 
     In order to assemble click wheel assembly  400 , click wheel faceplate  402 , center button plate  404 , and click wheel flex  408  are attached to click wheel support plate  410  (after the placement of shims  418 ) using fasteners  420 . Once assembled, adhesive  422  can be used to bond click wheel support plate  410  to a supporting structure (such as a printed circuit board, or PCB) already inserted and fixed within housing  100 . In order to prevent diving (movement by click wheel assembly  400  in the Z direction when a user applies pressure), click wheel support structure  424  can be used to provide additional support to click wheel assembly  400 . Click wheel support structure  424  can be formed of plastic or other related material. Prior to click wheel support plate  410  being placed and fixed within housing  100  and connected to main logic board using electrical connector  428 , click wheel support structure  424  can be dropped, or otherwise placed, within an accommodating space in the supporting structure (such as PCB) upon which click wheel support plate  410  is subsequently bonded. In the described embodiment, click wheel support structure  424  can include a central bore arranged to accommodate metallic spring  426 . Metallic spring  426  can be placed in physical contact with (metallic) click wheel support plate  410  and (metallic) housing  100 . In this way, metallic spring  426  can be used to both provide resilient support for click wheel assembly  400  and a conductive path to ground (i.e., between click wheel support plate  410  and housing  100 ). 
       FIG. 5  shows a front and rear view of m-frame assembly  500  in accordance with the described embodiments. M-frame assembly  500  can include some operational components mounted to metal frame  502  whereas the remaining operational components can be mounted to main logic board, or PCB  504 , that in turn can be mounted to metal frame  502 . Some components, such as display device  104 , are mounted to metal frame  502  at a fixed position, whereas other components can be mounted to metal frame  502  and yet be moved along the Y axis relative to display device  104 . Components mounted to metal frame  502  can be electrically connected to PCB  504  by way of connectors, or flex. Such connectors can include I/O flex  506 . I/O flex  506  can connect microphone module  518 , hold button circuit  510 , audio module  512 , and piezo-electric audio transducer (or more simply, piezo)  520  to PCB  504  using a single board to board (B2B) connector (not shown). Cross over flex  514  (shown in a folded state) can be used to connect display  104  and associated circuitry on PCB  504 . Microprocessor  516  and data port  522  can be connected directly to PCB  504 . In the described embodiment, data port  522  can be configured as a 30 pin connector. It should also be noted that in order to securely mate with an external data bus, data port  522  can include latching/alignment holes  523  on either or both sides of data port  522 . In order to prevent dust or other contamination from entering portable electronic device  10  at the latching holes  523  (with the possibility of obscuring camera lens  132 ) cosmetically appealing dust seals can be placed over latching holes  523 . By cosmetically appealing it can be meant that the resilient material (such as silicone) can be black or other dark color that cannot be readily seen within connector  522  from an outside observer. 
     Battery  524  which can be located at the rear of display device  104 . Battery  524  can operatively coupled to PCB  504  and its various components using a solder connector that couples battery  524  to a connector located on PCB  504 . Battery  524  can correspond to a rechargeable lithium polymer battery or a lithium ion prismatic cell. It should be noted that once battery  524  is connected to PCB  504 , m-frame assembly  500  can be functionally tested and if necessary, repaired, tuned, or otherwise modified prior to being inserted into housing  100  during the final assembly operation. Acoustic seal  526  can be used to form a front acoustic volume in conjunction with space  314  when m-frame assembly is slid into housing  100  forming a sliding seal between acoustic seal  516  and recess  314  to form a front acoustic volume. 
       FIG. 6  shows an embodiment of metal frame  502 . Metal frame  502  can provide a metallic support structure upon which a plurality of sub-assemblies formed of associated operational components can be mounted to form metal (m) frame assembly  500 . Metal frame  502  can be a multipart metal frame formed of at least two frame components formed of metal (such as stainless steel) that can be laser welded together. For example, metal frame  502  can be formed of display support portion  602  and main logic board (or printed circuit board, PCB) support portion  604  laser welded together. Metal frame  502  can also include a number of integrated features. These integrated features can improve operation of portable electronic device  10  (by providing a robust path to chassis ground) as well as being extremely useful in the assembly of both m-frame assembly  500  as well as the final assembly of portable electronic device  10 . 
     A plurality of ground tabs can be formed into metal frame  502  at various locations that can be used to provide a conductive path to chassis ground (housing  100 ). For example, front ground tab  606  can be used to provide a conductive path from click wheel assembly  400  to a front, lower portion of housing  100  whereas ground tabs  608  can be used to provide a conductive path to the rear portion of housing  100  whereas ground tabs  610  can provide good grounding for processor  516  and other components mounted to PCB  504 . 
     Another useful feature relates to a system for using rail-like structures to provide limited movement along the Y axis of components attached to metal frame  502 . In the described embodiment, rail system  612  can be formed by folding corresponding portions of frame  502  approximately 90 degrees (forming “U” channels in the process). Components mounted to rail system  612  can then be moved along the Y axis with respect to those components fixedly mounted to metal frame  502 , such as display  104 . This relative movement between components can be important since certain components, such as display  104  and audio jack  124 , must be precisely set within housing  100  for both functional and aesthetic reasons. For example, when m-frame assembly  502  is inserted into housing  100 , display  104  is fixed to metal frame  502  at display mounts  614 . (It should be noted that using the orientation shown in  FIG. 6 , display  104  is mounted to metal frame  502  at display mounts  614  from the bottom up such that display  104  is facing up as indicated.) As shown below, display  104  can be mounted to metal frame  502  at an LCD seal using adhesive (that acts as a bonding agent as well as dust shield). During assembly, metal frame  502  on which display  104  is bonded is slidably inserted into housing  100  until display  104  is centered within window  108 . Since it is crucial that display  104  remain centered, any movement of display  104  after being centered is not acceptable. However, since audio jack  124  and connector  126  must be set flush to the bottom of housing  100 , PCB  502  (along with data connector  126  and audio jack  124 ) must be able to move along the Y axis while display  104  remains stationary in order to easily align data connector  124  and audio jack  124 . 
     The architecture of metal frame  502  can facilitate the mounting of components onto metal frame  502  using what can be referred to as “book” type assembly techniques. Book type assembly techniques refers to installing components (such as PCB) on metal frame  502  by using an undercut feature on one side of metal frame  502  to place a component and a snap attaching feature on the other side of metal frame  502  to receive and snap in place the component. Accordingly, metal frame  502  includes an undercut feature  616  (side A) and a snapping feature  618  (side B). An assembly operator using the book assembly technique would use undercut feature  616  on side A to place a component (such as PCB  504 ) onto metal frame  502  and then, as one would close a book, lower the other side of PCB  504  to be snapped into place by snapping feature  618  at side B of metal frame  502 . Rail system  612  can then provide for moving the attached component in either direction along the Y axis. In this way, book type assembly limits the number of fasteners required and allows for substantially easier assembly. 
     In order to facilitate the transport of the acoustic energy provided by piezo-electric transducer  520 , a plurality of porting holes  620  can be punched into support plate  622 . In this way, an acoustic back volume can be created in part (using various leak paths to other interior portions of portable electronic device  10  as the remaining back volume) that in combination with an acoustic front volume (formed in conjunction with acoustic seal  524  and recess  314 ) can together provide a substantially improved use audio experience. 
       FIG. 7  shows an embodiment of display device  700  having cross over flex  702  in a folded state and an extended, or open, state. Display device  700  can include display  104  that can take the form of a liquid crystal display (LCD)  104  that can be bonded onto metal frame  502  at display mounts  616  using, for example, adhesive or other appropriate bonding agent. Display device  700  can be operatively connected to PCB  504  and its various components by way of cross over flex  702  at connector  704 . As shown, cross over flex  702  can be of sufficient length to be folded over to form a service loop. This service loop enables an assembly operator to move PCB  504  along the Y axis using rails  612  in order to more precisely align various components (such as audio jack) to openings in housing  100 . Furthermore, the cross over feature provides for greatly varying the location of the location where connector  704  can be used on PCD  504 . 
       FIG. 8A  shows an embodiment of microphone/camera assembly  800 . Camera assembly  800  can include camera module  508 , camera boot  802  and microphone  812 . Camera module  508  can include camera body  804  having camera opening  806 . Camera body  804  can be connected to PCB  504  by way of camera flex  808  and connector  810  but is free floating since it must be mounted, aligned and then sealed without moving PCB  504 . Camera alignment pin  814  (shown in  FIG. 8B ) can be used to fix camera module  508  into place using alignment hole  807  in camera arm  809 . Camera alignment pin  814  can be fix camera module  508  in place by being inserted into camera alignment pin hole  140  in housing  100 , pass through alignment hole  807  in camera arm  809  to rest in camera alignment pin recess  811 . In this embodiment shown in  FIG. 8B , camera alignment pin recess  811  can be machined from an inner surface of the front of housing  100 . It should be noted that recess  136  formed on the back of housing  100  can include camera opening  138 , camera alignment pin opening  140 , and microphone opening  142 . In the described embodiment, camera alignment pin opening  140  is covered by camera trim  132 . In this way, only microphone opening  142  and camera opening  138  (having camera lens  130  included therein) can be seen by a user. 
     In the described embodiment, camera flex  808  is “S” shaped. Being “S” shaped allows an assembly operator to move camera  804  in relation to PCB  504  in order to maintain the alignment of camera lens  130  and camera hole  806 . Camera boot  802  can be formed of silicone or other related material and can enclose camera module  508  providing protection against impact as well as environmental contaminants such as water, dust, etc. As shown in  FIG. 8C  in side view, camera boot  802  can include a number of camera boot grooves  820  that can be used to form dust seal as a result of camera module  508  being slideably inserted into housing  100 . This is particularly important due to the elevated probability of contamination from dust or other contaminants from the outside environment due to the proximity to camera  804  of the latching holes  523  present in port  522 . 
       FIG. 9  shows an embodiment of I/O flex  506 . I/O flex  506  can connect audio module  512 , microphone module  518 , hold button circuit  510  (by way of hold switch circuit connector  902 ), and piezo-electric audio transducer  520  to an external circuit (such as PCB  504  or a separate power supply) by way of board to board connector  904 . As shown, I/O flex  506  can include service loop portion  906  connecting body  908  of I/O flex  506  to hold button circuit connector  902 . Service loop portion  906  can provide the assembly operator the ability to adjust the position of hold switch  122 . An advantage to I/O flex  506  lies in the fact that once a particular component(s) (audio module  512 , for example) is/are connected to I/O flex  506 , connector  904  can be connected to an external power supply either directly or by way of another circuit  920  or circuit board (such as a test fixture) for stand-alone testing of any or all of the components connected thereto. 
       FIG. 10  shows a top and bottom view of audio module  512  in accordance with the described embodiments. Audio module  512  can be operatively coupled to the PCB  504  and its various components by way of I/O flex  506 . Audio module  512  can include an audio processing circuit  1002  and an audio jack  124 . Audio module  512  can be accommodated by audio module cut-out of metal frame  502  and mechanically coupled to the PCB  504  by way metal frame  502  so that the PCB  504  and audio module  512  can form an integrated structure. By way of example, they can be both be coupled to metal frame  502  together using fasteners, and/or snaps. Stiffener plate  1004  (seen in the bottom view of audio module  512 ) can be used to attach I/O flex  506  to audio module  512 . Stiffener plate  1004  can be formed of metal such as stainless steel (tin plated for example), gold, etc. Stiffener plate  1004  can also include stiffener arm  1006  used to prevent undue flexion in flex  506  by distributing stress more evenly across stiffener plate  1004 . Stiffener plate  1004  can also include a locator hole (not shown) arranged to accommodate locator post  1008  on PCB  504 . During the assembly of audio module  512  on PCB  504 , the locator hole can be mated to locator post  1008  in order to more easily align audio module  512 . Furthermore, by soldering locator post  1008  to stiffener plate  1004 , a suitable RF ground can be obtained providing for an FM antenna and associated circuitry to be ported through audio module  512 . It should be noted that metal hold down screw  1010  can securely fasten I/O flex  506  to audio module  512 . Metal hold down screw  1010  can provide additional grounding. 
       FIG. 11  shows a representation of cover glass assembly  1100  in accordance with the described embodiments. Display device  700  can include plastic chassis (p-chassis)  1102  providing support for components used to form display device  1100 . Such components can include display circuits layer  1104  (in the form of TFT or twisted field transistors) mounted between TFT glass layer  1106  and color filter glass layer  1108 . In the described embodiment, bottom polarizer layer  1110  can be attached to a bottom surface of TFT glass layer  1106  and a top polarizer layer  1112  can be mounted to an upper surface of color filter glass layer  1108 . LCD seal layer has a lower surface attached to upper surface of top polarizer layer  1112  and an upper surface bonded to metal frame  502  at display mounts  614 . In this way, in contrast to conventional approaches, p-chassis  1102  is not bonded directly to metal frame  502 . Black mask  1114  can be placed under cover glass  108 . Black mask  1114  can be used to define the viewable, or active area, of display  104 . Cover glass seal  1116  can be used to seal the area between black mask  1114  and metal frame  502 . 
       FIGS. 12-14  are flowcharts describing method  1200  of manufacturing a portable electronic device in accordance with the described embodiments. The method generally includes several operations including: the formation of the seamless housing, the insertion of fixing of m-frame assembly into the seamless housing, and the placement and fixing of stand-alone click wheel assembly into the seamless housing, and the placement end caps and cosmetic caps sealing the seamless housing. 
     Referring first to  FIG. 12  and the formation of the seamless housing, the operation starts with block  1202  where a tube is extruded. Following block  1202 , the operation proceeds to block  1204  where the extruded tube is cut to a desired length thereby exposing open ends. Following block  1204 , the operation proceeds to block  1206  where the access openings are formed in the extruded tube. By way of example, the access openings can be associated with a user interface of the electronic device, a display window, and a camera opening. Following block  1206 , the operation proceeds to block  1208  where at least two grooves are formed into a bottom inside surface of the extruded tube. By way of example, the grooves can be formed by machining the bottom inside surface of the extruded tube. Following block  1208 , the operation proceeds to block  1210  where an acoustic pocket is formed on the bottom inside surface of the extruded tube. The acoustic pocket can be formed by machining a specific amount of the extruded tube. Following block  1210 , resilient material, such as plastic is attached to the grooves at  1212 . 
     Referring now to  FIG. 13 , during assembly and referring to the open end of the seamless housing, m-frame assembly can be inserted into the lumen of the seamless housing as a single unit at  1214 . Metal frame essentially acts as a carrier for placing these components inside the seamless housing. During assembly, m-frame assembly can be inserted into lumen by sliding m-frame assembly through open end until display is centered within housing at  1216 . Once display is centered, cover glass can be placed on top of display at  1218 . Cover glass can then be seated to the display using adhesive and locked to housing by way of a flange on cover glass at  1220 . The force of pushing cover glass onto display is resisted by the resilient material attached to grooves causing display to be biased up in such as way as to affix display device to metal frame. 
     Turning now to  FIG. 14 , once display has been centered within window and fixed in place, cross over flex can allow PCB to be moved as necessary to align audio jack, camera, and piezo at  1222 . Once m-frame assembly and its constituent parts have been aligned to the appropriate positions vis a vis housing, click wheel assembly support can be dropped or otherwise placed into an appropriate space in PCB at  1224 . Once click wheel support is in place, click wheel assembly can be electrically connected to PCB at  1226  and then placed within the seamless housing in the click wheel opening at  1228 . Click wheel assembly can be aligned to housing and in particular, center button can be rotatably aligned as needed to conform to the shape of housing at  1230 . End caps can then be used to seal portable electronic device and to lock click wheel assembly in place at  1232 . Cosmetic covers can be placed over end caps at  1234 . 
     While this invention has been described in terms of several preferred embodiments, there are alterations, permutations, and equivalents, which fall within the scope of this invention. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. For example, although an extrusion process is preferred method of manufacturing the integral tube, it should be noted that this is not a limitation and that other manufacturing methods can be used (e.g., injection molding). 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 present invention.

Metadata:
Filing Date: 20090831
Publication Date: 20130226
Grant Date: 20130226
Priority Date: 20090831
Inventors: DABOV TEODOR
HOBSON PHILLIP M.
MONTEVIRGEN ANTHONY
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/1686", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R1/021", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49169", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49169", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49005", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49005", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1686", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/169", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4913", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/4913", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49002", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R31/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1637", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1635", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/181", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K13/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/169", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 43624614