PATENT DOCUMENT

Publication Number: US-10245767-B2
Application Number: US-201615368307-A
Country: US
Kind Code: B2

Title: Membrane for liquid-resistant devices and methods of making a membrane

Abstract:
A bracket assembly suitable for use with an electronic device is described. The bracket assembly may include a bracket body having a channel. The bracket assembly may further include a membrane embedded in the bracket body and designed to allow air, but not liquid (such as water), to pass through the membrane. The membrane may be at least partially surrounded by a membrane support molded to the membrane. The membrane and the membrane support may be disposed in a molding tool to receive a material used to mold the bracket body over the membrane and the membrane support. During the molding operation, the membrane support may act as a buffer to shield the membrane from temperature and pressure increases associated with the molding operation of the bracket body. The bracket assembly may improve the ability of the electronic device to prevent liquid ingress.

Claims:
What is claimed is: 
     
       1. A bracket assembly for preventing liquid ingress, the bracket assembly comprising:
 a bracket body comprising a through hole and a recess that surrounds the through hole; 
 a membrane carried by the bracket body and at least partially sealing the through hole such that a liquid is prevented from passing through the through hole, the membrane allowing air to pass through the through hole; and 
 a membrane support that defines a hollow ring coupled to an edge of the membrane, the membrane support further coupled to the bracket body and positioned within the recess. 
 
     
     
       2. The bracket assembly of  claim 1 , wherein the membrane support forms a buffer between the bracket body and the membrane. 
     
     
       3. The bracket assembly of  claim 2 , wherein the membrane support comprises an elastomeric material. 
     
     
       4. The bracket assembly of  claim 1 , wherein the bracket body comprises at least one of a polymeric material or polytetrafluoroethylene. 
     
     
       5. The bracket assembly of  claim 4 , wherein the membrane is free of contact with the bracket body. 
     
     
       6. The bracket assembly of  claim 1 , wherein the bracket body comprises:
 a first end having a threaded region for threaded engagement with an enclosure; and 
 a second end that carries the membrane, the second end opposite the first end. 
 
     
     
       7. The bracket assembly of  claim 6 , wherein the bracket body comprises a cavity at the first end, and wherein the membrane is adhesively secured with the bracket body at the first end by an adhesive disposed in the cavity such that the membrane is co-planar with respect to the bracket body. 
     
     
       8. An electronic device, comprising:
 an enclosure comprising an internal region, the enclosure further comprising a sidewall and an opening extending through the sidewall; 
 a touch-sensitive display assembly; 
 a transparent cover that overlays the touch-sensitive display assembly and couples with the enclosure; and 
 a bracket assembly at least partially disposed in the opening, the bracket assembly comprising:
 a bracket body comprising a through hole aligned with the opening, and 
 a membrane embedded in the bracket body and at least partially blocking the through hole, the membrane defining a seal that prevents liquid ingress from passing through the through hole and entering the internal region. 
 
 
     
     
       9. The electronic device of  claim 8 , further comprising a membrane support that defines a hollow ring coupled to an edge of the membrane and embedded in the bracket body, wherein the membrane is partially embedded in the membrane support such that the membrane support defines a buffer between the bracket body and the membrane. 
     
     
       10. The electronic device of  claim 8 , further comprising a band mechanically interlocked with the enclosure, the band used to secure the enclosure, and components within the enclosure, to an appendage of a user. 
     
     
       11. The electronic device of  claim 8 , wherein the bracket body comprises a polymeric material. 
     
     
       12. The electronic device of  claim 8 , wherein the membrane allow air to pass through the through hole and into the internal region. 
     
     
       13. The electronic device of  claim 8 , further comprising a sealing element positioned around the bracket body, the sealing element pressed against the opening. 
     
     
       14. The electronic device of  claim 8 , further comprising an operational component disposed in the internal region, wherein the operational component passes audible sound through the opening, the membrane, and the through hole. 
     
     
       15. A method for assembling a bracket assembly, the method comprising:
 molding a membrane support to a membrane in a first molding tool to define a membrane assembly, the membrane support defining a hollow ring coupled to an edge of the membrane; and 
 molding a bracket body to the membrane assembly, the bracket body comprising a through hole, wherein the membrane defines a seal to prevent an ingress liquid from passing through the through hole while allowing air to pass through the through hole, wherein molding the bracket body to the membrane assembly comprises forming a channel in the bracket body such that the through hole is at least partially blocked by the membrane. 
 
     
     
       16. The method of  claim 15 , wherein molding the bracket body to the membrane assembly comprises molding the bracket body only to the membrane support such that the membrane support defines a buffer between the bracket body and the membrane. 
     
     
       17. The method of  claim 16 , wherein molding the membrane support to the membrane comprises molding the membrane support only to an edge region of the membrane. 
     
     
       18. The method of  claim 15 , wherein molding the bracket body to the membrane assembly defines a recess in the bracket body, and wherein the membrane support is positioned in the recess. 
     
     
       19. The method of  claim 15 , wherein molding the bracket body to the membrane assembly comprises molding a housing for an operational component.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/270,503, filed on Dec. 21, 2015, and titled “MEMBRANE FOR LIQUID-RESISTANT DEVICES AND METHODS OF MAKING A MEMBRANE,” the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The described embodiments relate to an electronic device having water-resistant features. In particular, the described embodiments describe a membrane used to prevent liquid ingress at an opening of the electronic device. The membrane may include air-permeable characteristics, while also including liquid-resistant characteristics. The membrane may allow air to enter or pass, thereby allowing an audio driver installed in the electronic device to emit audible sound from the electronic device. The membrane may also be used to equilibrate the electronic device with respect to the external environment when, for example, the electronic device changes pressure due to increased or decreased elevation. 
     BACKGROUND 
     An electronic device may include one or more openings to enhance the functionality of the electronic device. For example, an opening may be used to receive an audio jack or to allow an audio speaker to pass audible sound through the electronic device. However, the openings allow an liquid ingress path into the electronic device. To overcome this issue, a screen may be disposed in the opening. 
     However, the screen may include several drawbacks. For example, the screen may include a relatively delicate material susceptible to damage during assembly (or sub-assembly) of the electronic device. Any damage or mishandling of the screen during manufacturing may limit the screen&#39;s ability to withstand liquid ingress, particularly when the liquid exerts a relatively high pressure to the screen. For example, when the electronic device is exposed to water, the screen may break down at greater depths (of the water). 
     SUMMARY 
     In one aspect, a bracket assembly for preventing liquid ingress is described. The bracket assembly may include a bracket body that includes a through hole. The bracket assembly may further include a membrane carried by the bracket body and at least partially sealing the through hole such that a liquid is prevented from passing through the through hole. However, the membrane may allow air to pass through the through hole. 
     In another aspect, an electronic device is described. The electronic device may include an enclosure that includes an internal region. The enclosure may further include a sidewall and an opening extending through the sidewall. The electronic device may further include a bracket assembly disposed in the opening. The bracket assembly may include a bracket body that includes a through hole aligned with the opening. The bracket assembly may further include a membrane embedded in the bracket body and at least partially blocking the through hole. In this regard, the membrane may define a seal that prevents liquid ingress from passing through the through hole and entering the internal region. 
     In another aspect, a method for assembling a bracket assembly is described. The method may include molding a membrane support to a membrane in a first molding tool to define a membrane assembly. The method may further include molding a bracket body to the membrane assembly. The bracket body may include a through hole. In some embodiments, the membrane may define a seal to prevent an ingress liquid from passing through the through hole while allowing air to pass through the through hole. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure 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. 1  illustrates a front view of an embodiment of an electronic device, in accordance with the descried embodiments; 
         FIG. 2  illustrates a rear isometric view of the electronic device shown in  FIG. 1 ; 
         FIG. 3  illustrates a partial isometric view of the electronic device shown in  FIG. 1 , showing an interior region of the enclosure and a bracket assembly prior to assembly with the enclosure; 
         FIG. 4  illustrates an exploded view of the bracket assembly shown in  FIG. 3 ; 
         FIG. 5  illustrates an enlarged front view of the electronic device shown in  FIG. 3 , further showing the bracket assembly installed in the enclosure; 
         FIG. 6  illustrates a cross sectional view of an embodiment of a membrane disposed in a molding tool; 
         FIG. 7  illustrates a cross sectional view of the membrane and the molding tool shown in  FIG. 6 , further showing the molding tool receiving a material to mold a membrane support to the membrane, in accordance with some described embodiments; 
         FIG. 8  illustrates a cross sectional view of the membrane and the membrane support shown in  FIG. 7 , with the membrane and the membrane support disposed in a second molding tool; 
         FIG. 9  illustrates a cross sectional view of the membrane, the membrane support, and the second molding tool shown in  FIG. 8 , further showing the second molding tool receiving a material to mold a bracket body to the membrane support, in accordance with some described embodiments; 
         FIG. 10  illustrates a cross sectional view of the membrane, the membrane support, and the bracket body removed from the second molding tool (shown in  FIG. 9 ); 
         FIG. 11  illustrates a cross sectional view of an alternate embodiment of a material received by a molding tool to mold a bracket body; 
         FIG. 12  illustrates a cross sectional view of the membrane and the bracket body removed from the molding tool shown in  FIG. 11 ; 
         FIG. 13  illustrates a cross sectional view of an alternate embodiment of a bracket assembly, showing a membrane secured with an end of a bracket body, in accordance with some described embodiments; 
         FIG. 14  illustrates a partial cross sectional view of an alternate embodiment of a bracket assembly that includes a sealing element partially disposed in a bracket body, in accordance with some described embodiments; 
         FIG. 15  illustrates an isometric view of an alternate embodiment of an assembly that incorporates a bracket assembly with an operational component, in accordance with some described embodiments; 
         FIG. 16  illustrates a partial isometric view of an alternate embodiment of an electronic device, showing an enclosure with a membrane embedded in the enclosure; and 
         FIG. 17  illustrates a flowchart showing a method for assembling a bracket assembly, in accordance with some described embodiments. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with some described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The described embodiments relate to a membrane, or seal, in an electronic device. The membrane is designed to enhance liquid-resistance capabilities of the electronic device in order to prevent liquid ingress (such as water ingress) from entering an opening of the electronic device. In this regard, the membrane is positioned in the opening to provide a liquid barrier for the electronic device. The membrane may also be designed as an air-permeable membrane that allows air to pass into and out of the opening. In some cases, the membrane includes polytetrafluoroethylene (“PTFE”). Further, in some cases, the membrane includes a stretched PTFE, causing the membrane to include small pores of varying sizes. Having an air-permeable, liquid-resistant membrane, the electronic device may include an operational component that relies on the opening for air transmission. Moreover, the operational component is protected from liquid ingress via the membrane. As non-limiting examples, the operational component may include an audio driver (audio speaker) that transmits audible sound through the opening and the membrane, a microphone or a barometric (pressure) sensor, each of which includes an electronic component and relies upon airflow. 
     In order to physically protect the membrane, the membrane may be part of a bracket assembly installed in the electronic device. One or more molding operations may be used to form the bracket assembly. For example, the membrane may undergo a molding operation to mold a membrane support to the membrane, thereby forming a membrane assembly. The membrane support may include an elastomeric material, such as rubber or elastomer. The membrane assembly may undergo a molding operation to mold a bracket body to the membrane assembly, and in particular, to the membrane support. The bracket body may include a polymeric material, such as plastic. The bracket body may also include a channel, or through hole, that is at least partially blocked by the membrane. When installed in the electronic device, the channel may align with the opening of the electronic device such that the membrane is positioned to block liquid entering the opening of the electronic device, thereby prevent the liquid from extending into the electronic device. 
     Molding operations may include compression molding, insert molding, and/or over molding. Also, one or more of these molding operations used to mold the bracket body may subject the membrane assembly to a relatively high pressure and temperature. However, the membrane support may act as a buffer between the bracket body, or molding thereof, and the membrane. As such, the membrane support may compress based on the increased pressure during the molding operation, and may also absorb increased temperatures during the molding operation. In this manner, the membrane support shields the membrane, and the membrane is less susceptible to damage during formation of the bracket body. This may lead to a more reliable membrane. 
     Also, in some cases, the molding operation of the bracket body includes mixing two or more chemicals that combine to form an epoxy, or resin. The formation by epoxy may include a molding operation that subjects the membrane to reduced temperature and pressure, relative to the molding operation using the polymeric material. In this manner, the membrane support may not be required as the membrane is not subject to the increased temperature and pressure. 
     In some cases, the enclosure of the electronic device is formed from a metal, such as aluminum (or aluminum alloy), or steel (including stainless steel). However, in some cases, the enclosure is formed by a molding operation similar to that previously described. Regarding the latter, the enclosure may be molded over the membrane such that the enclosure includes an opening that is at least partially blocked by the membrane. Accordingly, the membrane may be embedded in the enclosure during formation of the enclosure. 
     These and other embodiments are discussed below with reference to  FIGS. 1-17 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1  illustrates a front view of an embodiment of an electronic device  100 , in accordance with some described embodiments. In some embodiments, the electronic device  100  is a tablet device. In other embodiments, the electronic device  100  is a mobile wireless communication device, such as a smartphone. In some embodiments, the electronic device  100  is a wearable electronic device, similar to a watch. However, the electronic device  100  may include wireless communication capabilities, similar to previously described embodiments of an electronic device. As shown, the electronic device  100  may include an enclosure  102 . In some embodiments, the enclosure  102  is formed from a metal, which may include aluminum or stainless steel. In other embodiments, the enclosure  102  includes a metal alloy. Further, in some embodiments, the enclosure  102  includes a non-metal, such as ceramic. As shown, the enclosure  102  may include several sidewalls that combine to form an internal region (not shown) that receives several operational components for the electronic device  100 . 
     The electronic device  100  may further include a protective layer  104  secured with the enclosure  102 . The protective layer  104  may overlay a display assembly  106  (shown as a dotted line) designed to present visual content. In some embodiments, the protective layer  104  includes glass. In other embodiments, the protective layer  104  includes sapphire. The protective layer  104  may generally be any material that provides a protective and transparent cover for the display assembly  106 . Also, the display assembly  106  may include a touch-sensitive display designed to respond to a capacitive coupling with a touch-sensitive layer (not shown) of the display assembly  106 . 
     Also, the electronic device  100  may include one or more input features, such as a first input feature  108  and a second input feature  110 . The first input feature  108  and/or the second input feature  110  may include a dial designed to rotate in response to a rotational force. The first input feature  108  and/or the second input feature  110  may include a button designed to actuate in a direction toward the enclosure  102  in response to a force. The first input feature  108  and/or the second input feature  110  may be used to generate an input to or command to a processor circuit (not shown) in the electronic device  100 . In response to the input or command, the processor circuit may use an executable program stored on a memory circuit (not shown) to change the visual content displayed on the display assembly  106 . Also, the electronic device  100  may include one or more radio circuits (not shown) allowing the electronic device  100  to connect to a network as well as pair with an additional electronic device, such as a wireless communication device. 
     Also, although not shown, when the electronic device  100  is a wearable electronic device, the electronic device  100  may include one or more bands that wrap around an appendage (a wrist, for example) of a user. Also, the enclosure  102  may include cavities or partial openings to receive and mechanically interlock with bands, with the cavities allowing for the removal and replacement of the bands with different bands. 
       FIG. 2  illustrates a rear isometric view of the electronic device shown in  FIG. 1 , showing an opening  116  in the enclosure  102 . The opening  116  may serve several purposes. For example, the opening  116  may allow for emission of acoustical energy in the form of audible sound from an audio driver (or audio speaker) disposed in the electronic device  100 . The opening  116  may be used with other operational components, such as a microphone and/or a barometric (pressure) sensor. Moreover, the enclosure  102  may include additional openings (not shown) for the aforementioned operational components. Further, the openings may be disposed along various locations of the enclosure  102  based in part on a location of the operational component(s). Also, the openings may vary in size and shape. Further, the number of openings may vary according to the functionality of the electronic device  100 . For example, an additional opening (not shown) may be used in conjunction with the opening  116  to enhance the audible sound from the audio driver. 
     In some embodiments, the opening  116  (or an additional opening) is used as a vent for the electronic device  100  to allow air to flow into and/or out of the electronic device  100 . For example, the electronic device  100  may be subject to an elevation change that results in a pressure change at the electronic device  100  that causes airflow into or out of the electronic device  100  based on a pressure increase or pressure decrease, respectively. Accordingly, the opening  116  may allow the electronic device  100  to response to pressure changes by allowing the pressure inside the electronic device  100  to adjust and equilibrate with ambient pressure (outside the electronic device  100 ), which may prevent damage to the electronic device  100 . Further, the electronic device  100  may include a barometric sensor that uses the opening  116  (or an additional opening) to detect pressure exerted on the electronic device  100 , and provide a measurement of pressure exerted on the electronic device  100 . 
       FIG. 3  illustrates a partial isometric view of the electronic device  100  shown in  FIG. 1 , showing an internal region  120  of the enclosure  102  and a bracket assembly  130  prior to assembly with the enclosure  102 . The protective layer  104  and the display assembly  106  (shown in  FIG. 1 ), along with several internal components (such as battery, processor circuit, memory circuit, audio driver/speaker) are removed for purposes of illustration and simplicity. When installed, the bracket assembly  130  positioned in the opening  116  to limit or prevent ingress of liquid into the electronic device  100  via the opening  116 . However, the bracket assembly  130  may be designed to allow air to pass into and out of the enclosure  102 . In this regard, the bracket assembly  130  may include a membrane (not shown) that is both air-permeable and liquid-resistant. This may prevent any liquid passing partially through the opening  116  from further extending through the opening  116  and into the internal region  120 . This will be shown and described in further detail below. 
     As shown, the enclosure  102  may include a compartment  122  used to receive the bracket assembly  130 . The compartment  122  may be integrally formed with the enclosure  102  such that enclosure  102  and the compartment  122  combine to form a unitary structure, such as a single substrate of material. In some embodiments, the compartment  122  and the bracket assembly  130  include threaded regions such that the bracket assembly  130  may be in threaded engagement with the compartment  122 . In some embodiments (not shown), the enclosure  102  includes a threaded region for threaded engagement with the bracket assembly  130 , and the compartment  122  is not required. 
       FIG. 4  illustrates an exploded view of the bracket assembly  130  shown in  FIG. 3 . Several structural features may be shown as a partial cross sectional view for purposes of illustration. However, it should be noted that these features shown as a partial cross section may be a single, unitary piece. Further, these structural elements shown as a partial cross section can be formed by one of several molding operations, shown and described below. 
     As shown in  FIG. 4 , the bracket assembly  130  includes a bracket body  132  shown as a partial cross sectional view. In some embodiments, the bracket body  132  is formed from a polymeric material, such as plastic. In other embodiments, bracket body  132  is formed from an epoxy. In either embodiment, the bracket body  132  may be formed by a molding operation. The bracket body  132  may include a channel  134  that extends through the bracket body  132  from end to end (of the bracket body  132 ). In this regard, the channel  134  may be referred to as a through hole. The bracket body  132 , as shown, includes a particular size and shape. However, the size and the shape of the bracket body  132  may change according to other constraints, such as the size and the shape of the enclosure  102  and/or the opening  116  (shown in  FIG. 3 ). Accordingly, the size and the shape of the bracket body  132  may vary according the size and the shape of an embodiment of an electronic device  100 . 
     The bracket assembly  130  may further include a membrane  136  secured with the bracket body  132 . In some embodiments, the membrane  136  includes PTFE, which may include a stretched PTFE. Generally, the membrane  136  may include any material that is air-permeable and also liquid-resistant. In other words, the membrane  136  may include a material that allows air to pass through membrane  136  but also blocks liquids from passing through the membrane  136 . As shown in  FIG. 4 , the membrane  136  may be positioned in the channel  134  to form a barrier in the channel  134 . In particular, the membrane  136  may allow air to pass completely through the channel  134 , while also preventing liquids from passing completely through the channel  134 . 
     The bracket assembly  130  may further include a membrane support  138  surrounding the membrane  136 . The membrane support  138  is shown as a partial cross section. As shown in  FIG. 4 , the membrane support  138  may surround an edge region, or outer periphery, of the membrane  136 , while remaining free from a central region (other than the edge region) of the membrane  136 . The membrane support  138  and the membrane  136  may combine to define a membrane assembly embedded in the bracket body  132 . In some embodiments, the membrane support  138  includes an elastomer. In the embodiment shown in  FIG. 4 , the membrane support  138  includes rubber. Generally, the membrane support  138  may be formed from any compressible material that also withstands increased temperature and pressure associated with a molding operation to form the bracket body  132 . In this regard, the membrane support  138  may act as a buffer between the bracket body  132  and the membrane  136  to limit or prevent damage and/or deformation (such as wrinkling) of the membrane  136  during a molding operation (or in some cases, as assembly operation). This will be further discussed below. Also, although not shown, the bracket assembly  130  may further include a seal (such as a compressible O-ring) that surrounds the bracket body  132 . The seal may be designed to engage an enclosure of an electronic device (such as the enclosure  102 , shown in  FIG. 3 ) to further seal the electronic device from ingress and to secure the bracket assembly  130  with the enclosure. 
       FIG. 5  illustrates an enlarged front view of the electronic device  100  shown in  FIG. 3 , further showing the bracket assembly  130  installed in the enclosure  102 . As shown in the enlarged view, the bracket body  132 , and in particular, the channel  134 , may be aligned, and in some cases concentric, with the opening  116  of the enclosure  102 . Also, the membrane  136  may be positioned in the channel  134  to form a barrier in the channel  134 . In this manner, the membrane  136  may prevent, for example, liquid (such as water or a water-based solution) that enters the opening  116  and partially enters the channel  134  from further passing through the enclosure  102  and/or the channel  134 . Also, the membrane support  138  may further add structural support to the membrane  136 . The bracket assembly  130  may further include a sealing element  140  (such as a compressible O-ring) that surrounds the bracket body  132  and engages the enclosure  102  (or the compartment  122 ) to further seal the electronic device  100  from ingress that passes around the bracket assembly  130 , and to secure the bracket assembly  130  with the enclosure  102 . 
     Also, the electronic device  100  may include an operational component  144  disposed in the internal region  120 . In some embodiments, the operational component  144  is a barometric (pressure) sensor designed to measure pressure exerted on the electronic device  100 . In some embodiments, the operational component  144  is a microphone designed to receive audible sound from a user of the electronic device  100 . In the embodiment shown in  FIG. 4 , the operational component  144  is an audio driver designed to emit audible sound. The operational component  144  may rely on ambient air (external to the electronic device  100 ) for functionality and may also be sensitive to liquid ingress. In this regard, the membrane  136 , being an air-permeable and liquid-resistant membrane, may allow air to pass to and from the operational component  144 , while also shielding the operational component  144  from liquid ingress. Also, although not shown, an acoustic (or cosmetic) mesh may be disposed in the opening  116  to hide the bracket assembly  130 . 
       FIGS. 6-9  illustrate a process for forming a bracket assembly, in accordance with some described embodiments. The features and processes shown and described in  FIGS. 6-9  may be used to form the bracket assembly  130  (shown in  FIGS. 3-5 ). Further, the materials used to form the bracket assembly  130  shown in  FIGS. 3-5  may also be used in the processes shown and described in  FIGS. 6-9 . 
       FIG. 6  illustrates a cross sectional view of an embodiment of a membrane  236  disposed in a molding tool  250 . The molding tool  250  may be suitable for molding operations, such as a compression molding operation, an over molding operation, or an injection molding operation, as non-limiting examples. As shown, the molding tool  250  may include a first mold member  252  and a second mold member  254 . Although not shown, the molding tool  250  may include various configurations. The first mold member  252  and the second mold member  254  may be designed to accommodate the membrane  236 . Also, the first mold member  252  and the second mold member  254  may include cavities to receive a material, thereby allowing the material to mold with the membrane  236 . Although shown as a cross sectional view, the membrane  236  as well as the cavities in the first mold member  252  and the second mold member  254  may include a circular, cylindrical, or circumferential shape. Although not shown, various multi-sided shapes are also possible. 
       FIG. 7  illustrates a cross sectional view of the membrane  236  and the molding tool  250  shown in  FIG. 6 , further showing the molding tool  250  receiving a material  256  to mold a membrane support  238  to the membrane  236 , in accordance with some described embodiments. A dispenser  258  may supply the material  256  into the molding tool  250 . As shown in  FIG. 7 , the cavities of the first mold member  252  and the second mold member  254  allow the material  256  to extend around an edge region of the membrane  236  to form the membrane support  238 , and define a membrane assembly. 
       FIG. 8  illustrates a cross sectional view of the membrane  236  and the membrane support  238  shown in  FIG. 7 , with the membrane  236  and the membrane support  238  disposed in a second molding tool  260 . The second molding tool  260  may be suitable for molding operations, such as a compression molding operation, an over molding operation, or an injection molding operation. As shown, the second molding tool  260  may include a first mold member  262  and a second mold member  264 . Although not shown, the second molding tool  260  may include various configurations. The first mold member  262  and the second mold member  264  may be designed to accommodate the membrane  236  and the membrane support  238 . Also, the first mold member  262  and the second mold member  264  may include cavities to receive a material, thereby allowing the material to mold with the membrane  236  and the membrane support  238 . Although shown as a cross sectional view, the cavities in the first mold member  262  and the second mold member  264  may include a circular, cylindrical, or circumferential shape. However, various multi-sided shapes are also possible. 
       FIG. 9  illustrates a cross sectional view of the membrane  236 , the membrane support  238 , and the second molding tool  260  shown in  FIG. 8 , further showing the second molding tool  260  receiving a material  266  to mold a bracket body  232  to the membrane support  238 , in accordance with some described embodiments. A dispenser  268  may supply the material  266  into the molding tool  250 . The cavities of the first mold member  262  and the second mold member  264  allow the material  266  to extend around and mold to the membrane support  238 , as shown in  FIG. 8 , to define the bracket body  232 . 
     During the molding operation, the material  266  may be applied at relatively high temperatures. Further, when the molding operation includes, for example, a compression molding operation, the molding operation may provide pressure to the material  266  in order to extend the material  266  throughout the cavities of the first mold member  262  and the second mold member  264 . However, the membrane support  238  may provide a buffer such that the membrane support  238 , rather than the membrane  236 , absorbs the increased temperature and pressure during the molding operation and provides a temperature and pressure shield for the membrane  236 . Accordingly, the membrane support  238  may prevent the bracket body  232  from contacting the membrane  236 . In this regard, the membrane  236  may less susceptible to damage or wrinkling during a molding operation. 
       FIG. 10  illustrates a cross sectional view of the membrane  236 , the membrane support  238 , and the bracket body  232  removed from the second molding tool  260  (shown in  FIG. 9 ). These structural features may combine to define a bracket assembly  230 , in accordance with some described embodiments. Also, as shown, the molding operation may define a channel  234 , or through hole, in the bracket body  232  that extends through the bracket body  232  end to end. However, the membrane  236  may form a barrier in the channel  234  to prevent liquid from passing completely through the channel  234 . Also, the bracket assembly  230  may further include a sealing element  240  (such as an O-ring) that extends around the bracket body  232 . In some embodiments, as shown in  FIG. 10 , the sealing element  240  extends radially outward beyond the bracket body  232 . However, in some embodiments (not shown), the bracket body  232  may extend radially beyond the sealing element  240 . 
       FIGS. 11-15  illustrate various alternative designs to a bracket assembly. However, although not shown, in some cases, at least some features shown and described in the embodiments shown in  FIGS. 11-15  may be incorporated into previous embodiments, and features shown and described in previous embodiments may be incorporated into the embodiments shown in  FIGS. 11-15 . Also, although cross sectional views are shown in  FIGS. 11-15 , the embodiments may include circular, cylindrical, or circumferential designs. 
     A bracket assembly may be formed from different materials, and as such, may alter the formation process. For example,  FIG. 11  illustrates a cross sectional view of an alternate embodiment of a material  356  received by a molding tool  350  to mold a bracket body  332  with a membrane  336 . The material  356  may include an epoxy form by combining two or more chemical compounds that form a reaction to cure the material  356 . In this manner, the molding operation may provide less pressure and a lower temperature, thereby reducing the pressure and temperature exerted on the membrane  336 . In this regard, the molding tool  350  may be suitable to simply create a cast that defines the bracket body  332 . As shown, the molding tool  350  may include a first mold member  352  and a second mold member  354 . Although not shown, the molding tool  350  may include various configurations. The first mold member  352  and the second mold member  354  may be designed to accommodate the membrane  336 . Also, a dispenser  358  may supply the material  356  into the molding tool  350 . The dispenser  358  may include two or more materials that combine to form an epoxy (or resin) that fills the molding tool  350 . The epoxy may allow for a molding operation with lower temperatures and pressures, as compared to the previously described molding operation for a bracket body  232  (shown in  FIG. 9 ). The cavities of the first mold member  352  and the second mold member  354  allow the material  356  to extend around an edge region of the membrane  336 . Also, based on the relatively low temperatures and pressures of the material  356 , the bracket body  332  may be in direct contact with the membrane  336 . 
       FIG. 12  illustrates a cross sectional view of the membrane  336  and the bracket body  332  removed from the molding tool  350  (shown in  FIG. 11 ). The bracket body  332  and the membrane  336  may define a bracket assembly  330  that requires fewer parts, as a membrane support (shown in previous embodiments) is not required to provide a buffer for the membrane  336 . While an epoxy is used to form the bracket body  332  shown in  FIG. 12 , other liquid-based materials that cure without substantially increased temperature and pressure may be used. Also, similar to previous embodiments, the bracket assembly  330  may include a channel  334  that extends through the bracket body  332 , with the membrane  336  forming a barrier in the channel  334 . In this manner, the bracket assembly  330  may include air-permeable, liquid-resistant characteristics based on the membrane  336 . 
       FIG. 13  illustrates a cross sectional view of an alternate embodiment of a bracket assembly  430 , showing a membrane  436  secured with a first end  442  of a bracket body  432 , in accordance with some described embodiments. In some embodiments, the first end  442  is associated with an interior region of the bracket assembly  430  and a second end  444  (opposite the first end  442 ) is associated with an exterior region of the bracket assembly  430 . In this manner, the second end  444  may abut an enclosure of an electronic device (previously described) and align with an exterior surface of the enclosure, while the first end  442  is off separated from the exterior surface. Also, the membrane  436  may be adhesively secured with the bracket body  432  by an adhesive  438 . Further, the bracket body  432  may include a cavity to receive the membrane  436  such that the membrane  436  is co-planar, or flush, with respect to the first end  442 . In some cases, when the bracket body  432  is formed from a molding operation that includes relatively high temperatures and pressures, the membrane  436  may be assembled with the bracket body  432  subsequent to the molding operation. Also, similar to previous embodiments, the bracket assembly  430  may include a channel  434  that extends through the bracket body  432 , with the membrane  436  forming a barrier in the channel  434 . In this manner, the bracket assembly  430  may include air-permeable, liquid-resistant characteristics based on the membrane  436 . 
     In addition,  FIG. 13  illustrates threaded regions of the bracket body  432 . For example, in some embodiments, the bracket body  432  includes a first threaded region  446 . In the embodiment shown in  FIG. 13 , the bracket body  432  includes a first threaded region  446  and a second threaded region  448 . Both the first threaded region  446  and the second threaded region  448  may extend circumferentially around the bracket body  432 . This may allow installation of the bracket assembly  430  by a threaded engagement between a threaded region (not shown) of an enclosure of an electronic device and both the first threaded region  446  and the second threaded region  448 . 
       FIG. 14  illustrates a partial cross sectional view of an alternate embodiment of a bracket assembly  530  that includes a sealing element  538  partially disposed in a bracket body  532 , in accordance with some described embodiments. The sealing element  538  may be embedded circumferentially in the bracket body  532  by a molding operation (not shown). However, bracket assembly  530  may include a channel  534  that defines a port (or at least part of a port) of an electronic device (not shown), with the port designed to receive an external device, such as an audio jack, a data transfer cable, or a power cable. When any one of these the structural features enters the bracket assembly  530 , the structural feature may engage sealing element  538 , creating a liquid-resistant seal that prevents liquid ingress through the bracket assembly  530 . Accordingly, the bracket assembly  530  may include liquid-resistant characteristics without using a membrane (shown in previous embodiments). 
       FIG. 15  illustrates an isometric view of an alternate embodiment of an assembly  610  that incorporates a bracket assembly  630  with an operational component  654 , in accordance with some described embodiments. The operational component  654  may include any operational component previously described. As shown, the assembly  610  may incorporate the operational component  654  with the bracket assembly  630  to facilitate assembly into an electronic device (not shown). For example, a bracket body  632  of the bracket assembly  630  may include a size and a shape to receive the operational component  654 . Accordingly, the bracket body  632  may define a housing for the operational component  654 . In this manner, installing the assembly  610  may include a single step as opposed to multiple steps of installing the bracket assembly  630  and (separately) installing the operational component  654 . As shown, the operational component  654  may include an audio driver that passes acoustical energy in the form of audible sound through a channel  634  as well as a membrane  636 , while the membrane  636  may shield the operational component  654  from liquid ingress. Also, the assembly  610  may include a sealing element  640  to provide additional protection from liquid ingress passing around the assembly  610 . 
       FIG. 16  illustrates a partial isometric view of an alternate embodiment of an electronic device  700 , showing an enclosure  702  with a membrane  736  embedded in the enclosure  702 , in accordance with some described embodiments. The membrane  736  may include any feature or features previously described for a membrane. In some embodiments, the enclosure  702  includes a moldable polymeric material. In this regard, in some embodiments, the enclosure  702  undergoes a molding operation using a molding tool (not shown). The molding tool may be designed to receive the membrane  736 . Then, the molding tool may receive a material used to form the enclosure  702  and mold the enclosure  702  over the membrane  736 . In the enlarged view, the enclosure  702  may include an opening  716  defining a channel  734  that is at least partially blocked by the membrane  736 . The opening  716  may otherwise pass through the enclosure  702 . Accordingly, the channel  734  may define a hollow region of the enclosure  702  formed during the molding operation. The opening  716  may be used by an operational component (not shown) disposed in the enclosure  702 , while the membrane  736  offers an air-permeable and liquid-resistant membrane. Also, it should be understood that a material used to form the enclosure  702  should be selected so as to not cause damage to the membrane  736  during the molding operation. As shown, the enclosure  702 , already having the membrane  736 , may not require additional liquid-resistant modifications based on the membrane  736 . 
       FIG. 17  illustrates a flowchart  800  showing a method for assembling a bracket assembly, in accordance with some described embodiments. In step  802 , a membrane support is molded to a membrane in a first molding tool to define a membrane assembly. The membrane may be placed in a molding tool to undergo a molding operation. The membrane support may include a rubber or elastomeric material, or another compressible material. The membrane may be an air-permeable and liquid-resistant membrane. 
     In step  804 , a bracket body to the membrane assembly. The bracket body may include a polymer, or polymeric material, such as plastic. The membrane assembly may be placed in a second molding tool to undergo a molding operation that defines the bracket body. The bracket body may include a channel. The channel may extend through the bracket body, but may be at least partially blocked by the membrane. Once assembled, the membrane may define a seal to prevent an ingress liquid from passing entirely through the channel while allowing air to pass through the membrane and the channel. The bracket assembly may be used in an electronic device to prevent liquid ingress into an opening of the electronic device. 
     Other features may be included. For example, a sealing element (such as an O-ring) may be positioned around the bracket body. Also, the bracket body may include a threaded region for threaded engagement with the enclosure, or a feature in an interior region of the enclosure. 
     While several embodiments show a wearable electronic device, several other electronic devices may incorporate an embodiment of a bracket feature (or features) described herein. For example, a laptop computing device, a desktop computing device, a mobile wireless communication device, or a tablet device may include at least one embodiment of a bracket assembly. 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20161202
Publication Date: 20190402
Grant Date: 20190402
Priority Date: 20151221
Inventors: LI, XUESEN
BUSHNELL, TYLER S.
WERNER, CHRISTOPHER M.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04R1/44", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R2231/001", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R31/003", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R7/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2307/204", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14336", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C45/2618", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2995/0069", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2463/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/14131", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01L9/0044", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R2307/025", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2627/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/1671", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K7/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2995/0065", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3481", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/1671", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2627/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R7/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/14131", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/2618", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R2307/025", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K7/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2995/0069", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/44", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R2307/204", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01L9/0044", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2995/0065", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3481", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R31/003", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2463/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2231/001", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14336", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 59065365