PATENT DOCUMENT

Publication Number: US-9030839-B2
Application Number: US-201313855688-A
Country: US
Kind Code: B2

Title: Track pad acoustic features related to a portable computer

Abstract:
The present application describes various embodiments of systems and methods for providing internal and external components for portable computing devices having a thin profile. More particularly, the present application describes internal components configured to fit within a relatively thin outer enclosure, wherein the internal components comprise at least one external interface, such as, for example, a track pad interface.

Claims:
What is claimed is: 
     
       1. A track pad, comprising:
 a cover having a first end and a second end opposite the first end, the first end of the cover configured to be pivotally coupled to a case of a portable computing device; 
 a printed circuit board (PCB) coupled with an interior facing surface of the cover and proximate the second end of the cover; 
 a touch sensor in communication with the PCB and disposed between the PCB and the cover; and 
 a switch directly coupled to the touch sensor and extending into an opening defined by the PCB, wherein the switch is configured to be actuated by a support member of the portable computing device that extends into the opening in the PCB when the cover pivots about the first end. 
 
     
     
       2. The track pad of  claim 1 , wherein the PCB defines a protrusion that extends past the second end of the cover and is configured to engage the case. 
     
     
       3. The track pad of  claim 2 , wherein the touch sensor extends past the protrusion and is configured to conceal a gap between the cover and the case. 
     
     
       4. The track pad of  claim 1 , wherein a vertical position of the support member is adjustable so that a distance the cover pivots before the switch is actuated by the support member changes with adjustment of the vertical position of the support member. 
     
     
       5. The track pad of  claim 1 , further comprising at least one acoustic transmission member configured to guide acoustic energy within the track pad, wherein the acoustic energy is imparted to the cover by actuating and de-actuating the switch. 
     
     
       6. A method for assembling a track pad in a portable computing device, the method comprising:
 pivotally coupling a first end of a cover to a case of the portable computing device; 
 coupling a printed circuit board (PCB) with an interior facing surface of a second end of the cover, the second end opposite the first end 
 positioning a touch sensor between the PCB and the cover; 
 mechanically coupling a switch to the touch sensor proximate an opening defined by the PCB; and 
 positioning a support member proximate the opening so that when the cover pivots the support member activates the switch through the opening in the PCB. 
 
     
     
       7. The method of  claim 6 , further comprising: forming a protrusion on the PCB that extends past the second end of the cover and is configured to engage the top case. 
     
     
       8. The method of  claim 7 , further comprising: extending the touch sensor past the protrusion; and
 concealing a gap between the cover and the case. 
 
     
     
       9. The method of  claim 6 , further comprising: adjusting a vertical engagement position of the support member so that a distance the second end of the cover travels before actuating the switch changes. 
     
     
       10. The method of  claim 9  wherein adjusting a vertical engagement position comprises:
 fitting a gauge fixture having controlled dimensions within a threaded hole in the support member; and 
 constraining the support member with a collar included in the gauge fixture configured to constrain a set screw. 
 
     
     
       11. The method of  claim 10 , further comprising contacting a portion of the switch with the gauge fixture through the threaded hole. 
     
     
       12. The method of  claim 11  further comprising measuring a distance between the switch and the support member with an optical measuring device and the gauge fixture having controlled dimensions. 
     
     
       13. A track pad, comprising:
 a cover having a first end and a second end opposite the first end, the first end of the cover configured to pivotally couple to a case of a portable computing device; 
 a printed circuit board (PCB) mechanically coupled to an interior facing surface of the second end of the cover; 
 a touch sensor disposed between the PCB and the cover; 
 a switch mechanically coupled to the touch sensor and configured to actuate upon pivoting the cover about the first end; and 
 at least one acoustic transmission member coupled to the cover in a position proximate to the first end of the cover and configured to guide acoustic energy within the track pad, wherein the acoustic energy is imparted to the cover by actuating and de-actuating the switch. 
 
     
     
       14. The track pad of  claim 13  further comprising: a support member that actuates the switch through an opening in the PCB when the cover pivots about the first end. 
     
     
       15. The track pad of  claim 14 , wherein a vertical position of the support member is adjustable so that a distance the cover pivots before the switch is actuated by the support member changes with adjustment of the vertical position of the support member. 
     
     
       16. The track pad of  claim 15  , wherein the at least one acoustic transmission member is further coupled to the case of the portable computing device. 
     
     
       17. The track pad of  claim 13 , wherein the at least one acoustic transmission member is configured to guide at least a portion of the acoustic energy from the cover to the case. 
     
     
       18. The track pad of  claim 13 , wherein the at least one acoustic transmission member is further configured to dampen at least a portion of the acoustic energy. 
     
     
       19. A portable computing device, comprising:
 a lid portion configured to include a display; 
 a base portion including a top case and bottom case, pivotally coupled to the lid portion, the top case comprising:
 a track pad zone configured to support a track pad, wherein the track pad comprises a cover having a first end and a second end opposite the first end, the first end of the cover configured to be pivotally coupled to the top case, a printed circuit board (PCB) coupled to an interior facing surface of the cover, a touch sensor in communication with the PCB and coupled to the second end of the cover, wherein the touch sensor is in communication with the PCB and disposed between the PCB and the cover, and at least one acoustic transmission member is coupled to the cover proximate the first end of the cover and configured to guide acoustic energy within the track pad. 
 
 
     
     
       20. The portable computing device of  claim 19 , wherein the at least one acoustic transmission member is configured with a first side coupled to the cover proximate to the first end of the cover and a second side in contact with the top case. 
     
     
       21. The portable computing device of  claim 19  further comprising:
 a switch directly coupled to the touch sensor and extending into an opening defined by the PCB, wherein the switch is configured to be actuated by a support member of the portable computing device that extends into the opening in the PCB when the cover pivots about the first end. 
 
     
     
       22. The portable computing device of  claim 21 , wherein the support member comprises a vertically adjustable set screw configured to set a distance the cover travels when the cover pivots about the first end when the switch is actuated by the support member. 
     
     
       23. The portable computing device of  claim 19 , wherein the at least one acoustic transmission member is further coupled to the top case of the portable computing device. 
     
     
       24. The portable computing device of  claim 19 , wherein the at least one acoustic transmission member is configured to guide an acoustic energy from the cover to the top case. 
     
     
       25. The portable computing device of  claim 21  , wherein the at least one acoustic transmission member is further configured to dampen at least a portion of an acoustic energy generated upon actuation of the switch. 
     
     
       26. A method for assembling a track pad, the method comprising:
 providing a cover having a first end and a second end opposite the first end, the first end of the cover configured to be pivotally coupled to a case of a portable computing device; 
 coupling a printed circuit board (PCB) to an interior facing surface of the cover and proximate the second end of the cover; 
 coupling a touch sensor between the PCB and the cover; and, 
 mechanically and electrically coupling a switch to an interior facing surface of the touch sensor, wherein the switch is configured to be actuated by a support member of the portable computing device that extends into an opening in the PCB overlapping the switch when the cover pivots about the first end. 
 
     
     
       27. The method of  claim 26  wherein the support member comprises an adjusting screw, wherein the adjusting screw is configured to locate a position at which the switch is activated when the cover pivots about the first end. 
     
     
       28. The method of  claim 27  wherein coupling the switch to the touch sensor comprises placing a support member through the opening to allow an inflection of the switch upon actuating the support member. 
     
     
       29. The method of  claim 26  wherein providing a cover comprises:
 pivotally coupling the first end of the cover to a case of the portable computing device; and 
 decoupling the second end of the cover from the case of the portable computing device.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This U.S. Patent Application claims priority under 35 USC 119(e) to U.S. Provisional Patent Application No. 61/715,810 filed Oct. 18, 2012 entitled “Trackpad Features of a Portable Computer” by Jang et al. and to U.S. Provisional Patent Application No. 61/715,820 filed Oct. 18, 2012 entitled “Manufacturing Features Related to an Internal Components of a Portable Computer” by Espiritu et al both of which are incorporated by reference in its entirety for all purposes. 
    
    
     TECHNICAL FIELD 
     The embodiments described herein relate generally to portable computing devices. More particularly, the present embodiments relate to internal components that may be included in portable computing devices which include at least one external interface, for example, a track pad interface. 
     BACKGROUND 
     The outward appearance of a portable computing device, including its design and its heft, is important to a user of the portable computing device, as the outward appearance contributes to the overall impression that the user has of the portable computing device. Dimensions of the portable computing device may be particularly important to a user. 
     One design challenge associated with the manufacture of portable computing devices is the design of internal components as they relate to an enclosure of the portable computing device. When the design of the enclosure is selected to be relatively compact, the internal components within the enclosure must be designed and configured to fit within the compact space of the enclosure. Internal component functionality should not be compromised to because of a lack of implementation space. 
     Therefore, it is desirable for internal components of a portable computing device to have good functionality and to have a compact configuration to allow integration into relatively compact volumes. 
     SUMMARY 
     Embodiments of improved internal components for a portable computing device are provided. In one embodiment a track pad includes a cover, a touch sensor, and a printed circuit board. The printed circuit board may be connected to the touch sensor and coupled to the cover at an end thereof that is free to pivot. Thereby, the printed circuit board may stiffen the end of the cover. This may facilitate use of a dome switch coupled to the printed circuit board and configured to operate upon pivoting the cover without use of a separate stiffener for the cover. 
     According to another embodiment, a portable computing device includes a base portion including a top case, the top case including a set screw, bottom case and a track pad coupled to the top case. The track pad comprises a cover extending from a first end to a second end, the first end of the cover pivotally coupled to the top case with the second end decoupled from the top case, a touch sensor, a printed circuit board in communication with the touch sensor and coupled to the second end of the cover, and a switch coupled to the touch sensor and configured to actuate upon pivoting the cover about the first end and contacting the set screw. 
     According to another embodiment, a fixture is provided to calibrate a set screw position used in a track pad assembly. The fixture can include a switch coupled to a touch sensor, a support member including a threaded hole positioned over the switch, a gauge fixture configured to fit within the threaded hole and a set screw disposed on the gauge fixture. 
     In another embodiment, a method is provided for attaching ground tabs coupled to a touch pad to a printed circuit board can include the steps of receiving the touch pad and ground tab, where a first end of the ground tab is coupled to the touch pad, bending a second end of the ground tab to form an acute angle between the second end of the ground tab and the touch pad, arranging the printed circuit board to contact the ground tab in a contact region, heating the contact region bonding the printed circuit board to the ground tab and folding the ground tabs to configure printed circuit board to contact the touch pad. 
     Embodiments of acoustic components related to a track pad for a portable computing device are provided. In one embodiment, a track pad can include a cover extending from a first end to a second end where the first end of the cover can be configured to pivotally couple to a case of the portable computing device with the second end decoupled from the case. The track pad can also include a touch sensor and a printed circuit board in communication with the touch sensor and coupled to the second end of the cover where the printed circuit board is configured to support the second end of the cover. The track pad can include a dome switch coupled to the touch sensor and configured to actuate upon pivoting the cover about the first and at least one acoustic transmission member configured to guide acoustic energy within the track pad. 
     In another embodiment, a portable computing device can include a lid portion configured to include a display, a base portion including a top case and a bottom case pivotally coupled to the lid portion where the top case can include a palm rest zone, a keyboard zone and a track pad zone, configured to support a track pad, the track pad including a cover with a first end and a second end, the first end pivotally coupled to the top case and the second end decoupled from the top case, a touch sensor, a printed circuit board in communication with the touch sensor and coupled to the second end of the cover where the printed circuit board is configured to support the second end of the cover and at least one acoustic transmission member configured to guide acoustic energy within the track pad. 
     In yet another embodiment, a portable computing device can include a base portion including a top and a bottom case and a track pad, the track pad including a cover extending from a first end to a second end, the first end of the cover pivotally coupled to the top case with the second end decoupled from the top case, a touch sensor, a printed circuit board in communication with the touch sensor and coupled to the second end of the cover, the printed circuit configured to support the second end of the cover, a dome switch coupled to the touch sensor and configured to actuate when the cover is pivoted about the first end and at least one acoustic transmission member configured to guide acoustic energy within the track pad. 
     Other apparatuses, methods, features and advantages of the disclosure will be or will become apparent to one with 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, be within the scope of the disclosure, and be protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The included drawings are for illustrative purposes and serve only to provide examples of possible structures and arrangements for the disclosed apparatuses, assemblies, methods, and systems. These drawings in no way limit any changes in form and detail that may be made to the disclosure by one skilled in the art without departing from the spirit and scope of the disclosure. 
         FIG. 1  shows a front facing perspective view of an embodiment of the portable computing device in the form of portable computing device in an open (lid) state according to an example embodiment of the present disclosure, 
         FIG. 2  shows the portable computing device of  FIG. 1  in a closed (lid) configuration that shows rear cover and logo according to an example embodiment of the present disclosure. 
         FIG. 3  shows another embodiment of the portable computing device in an open state according to an example embodiment of the present disclosure. 
         FIG. 4  shows an external view of the bottom case of the portable computing device of  FIG. 1  or  3  according to an example embodiment of the present disclosure; 
         FIG. 5  illustrates a top case with an integrated support system according to an example embodiment of the present disclosure. 
         FIG. 6  illustrates a view of the top case of  FIG. 5  highlighting the relationship between integrated support system and various structural components according to an example embodiment of the present disclosure. 
         FIG. 7  illustrates a bottom view of a track pad according to an embodiment of the present disclosure. 
         FIG. 8  schematically illustrates an exploded view of the track pad of  FIG. 7 . 
         FIG. 9  illustrates an exploded side view of the track pad of  FIG. 7 . 
         FIG. 10  illustrates an expanded view of acoustic foam of the track pad of  FIG. 7 . 
         FIG. 11  illustrates an expanded view of a support system of a portion of the track pad of  FIG. 7 . 
         FIG. 12  illustrates a method for assembling a track pad according to an example embodiment of the present disclosure. 
         FIG. 13  illustrates a cross sectional view of dome switch and support plate arranged in a fixture to calibrate a set screw position. 
         FIGS. 14A-14F  illustrate steps for controllably forming a service loop in ground tabs. 
         FIG. 15  is an isometric view of printed circuit board positioned over ground film with ground tabs. 
     
    
    
     DETAILED DESCRIPTION 
     Representative applications of apparatuses and methods according to the presently described embodiments are provided in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the presently described embodiments can be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the presently described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     The following relates to a portable computing device such as a laptop computer, net book computer, tablet computer, etc. The portable computing device can include a multi-part housing having a top case and a bottom case joining at a reveal to form a base portion. The portable computing device can have an upper portion (or lid) that can house a display screen and other related components whereas the base portion can house various processors, drives, ports, battery, keyboard, track pad and the like. The top case and the bottom case can each be joined in a particular manner at an interface region such that the gap and offset between top and bottom cases are not only reduced, but are also more consistent from device to device during the mass production of devices. These general subjects are set forth in greater detail below. 
     In a particular embodiment, the lid and base portion can be pivotally connected with each other by way of what can be referred to as a clutch assembly. The clutch assembly can be arranged to pivotally couple the base portion to the lid. The clutch assembly can include at least a cylindrical portion that in turn includes an annular outer region, and a central bore region surrounded by the annular outer region, the central bore suitably arranged to provide support for electrical conductors between the base portion and electrical components in the lid. The clutch assembly can also include a plurality of fastening regions that couple the clutch to the base portion and the lid of the portable computing device with at least one of the fastening regions being integrally formed with the cylindrical portion such that space, size and part count are minimized. 
     The multipart housing can be formed of a strong and durable yet lightweight material. Such materials can include composite materials and or metals such as aluminum. Aluminum has a number of characteristics that make it a good choice for the multipart housing. For example, aluminum is a good electrical conductor that can provide good electrical ground; it can be easily machined and has well known metallurgical characteristics. The superior conductivity of aluminum provides a good chassis ground for internal electrical components arranged to fit and operate within the housing. The aluminum housing also provides a good electromagnetic interference (EMI) shield protecting sensitive electronic components from external electromagnetic radiation as well as reducing electromagnetic radiation emanating from the portable computing device. 
     The top case can include a cavity, or lumen, into which a plurality of operational components can be inserted during an assembly operation. In the described embodiment, the operational components can be inserted into the lumen and attached to the top case in a “top-bottom” assembly operation in which top-most components are inserted first, followed by components in a top-down arrangement. For example, the top case can be provided and shaped to accommodate a keyboard module. The keyboard module can include a keyboard assembly formed of a plurality of keycap assemblies and associated circuitry, such as a flexible membrane on which can be incorporated a switching matrix and protective feature plate. Therefore, following the top-bottom assembly approach, the keyboard assembly is first inserted into the top case followed by the flexible membrane and then the feature plate that is attached to the top case. Other internal components can then be inserted in a top to bottom (when viewed from the perspective of the finished product) manner. 
     In addition to the keyboard, the portable computing device can include a touch sensitive device along the lines of a track pad, touch screen, etc. In those embodiments where the portable computing device includes a track pad the track pad can be formed from a glass material. The glass material provides a cosmetic surface and is the primary source of structural rigidity for the track pad. The use of the glass material in this way significantly reduces the overall thickness of the track pad compared to previous designs. The track pad can include circuitry for processing signals from a sensor associated with the track pad. In one embodiment, the circuitry can be embodied as a printed circuit board (PCB). The PCB can be formed of material and placed in such a way that provides structural support for the track pad as well as increased rigidity. Thus, a separate track pad support is eliminated. 
     Due at least to the strong and resilient nature of the material used to form the multipart housing; the multipart housing can include a number of openings having wide spans that do not require additional support structures. Such openings can take the form of ports that can be used to provide access to internal circuits. The ports can include, for example, data ports suitable for accommodating data cables configured for connecting external circuits. The openings can also provide access to an audio circuit, video display circuit, power input, etc. 
     In one embodiment, the top case can be formed from a single billet of aluminum that is machined into a desired shape and size. The top case can include an integrated support system that adds to the structural integrity of the top case. The integrated support system can be continuous in nature in that there are no gaps or breaks. The integrated support system can be used to provide support for individual components (such as a keyboard). For example, the integrated support system can take the form of ribs that can be used as a reference datum for a keyboard. The ribs can also provide additional structural support due to the added thickness of the ribs. The ribs can also be used as part of a shield that help to prevent light leaking from the keyboard as well as act as a Faraday cage that prevents leakage of extraneous electromagnetic radiation. 
     The continuous nature of the integrated support system can result in a more even distribution of an external load applied to the multi-part housing resulting in a reduced likelihood of warping, or bowing that reduces risk to internal components. The integrated support system can also provide mounting structures for those internal components mounted to the multi-part housing. Such internal components include a mass storage device (that can take the form of a hard disk drive, HDD, or solid state drive, SSD), audio components (audio jack, microphone, speakers, etc.) as well as input/output devices such as a keyboard and track pad. 
     These and other embodiments are discussed below with reference to  FIGS. 1-12 . 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. 
       FIGS. 1-6  show various views of the portable computing device in accordance with various embodiments.  FIG. 1  shows a front facing perspective view of an embodiment of the portable computing device in the form of portable computing device  100  in an open (lid) state. Portable computing device  100  can include base portion  102  formed of bottom case  104  fastened to top case  106 . Base portion  102  can be pivotably connected to lid portion  108  by way of clutch assembly  110  hidden from view by a cosmetic wall. Base portion  102  can have an overall uniform shape sized to accommodate clutch assembly  110  and inset portion  112  suitable for assisting a user in lifting lid portion  108  by, for example, a finger. Top case  106  can be configured to accommodate various user input devices such as keyboard  114  and track pad  116 . Keyboard  114  can include a plurality of low profile keycap assemblies each having an associated key pad  118 . In one embodiment, an audio transducer (not shown) can use selected portions of keyboard  114  to output audio signals such as music. In the described embodiment, a microphone can be located at a side portion of top case  106  that can be spaced apart to improve frequency response of an associated audio circuit. 
     Each of the plurality of key pads  118  can have a symbol imprinted thereon for identifying the key input associated with the particular key pad. Keyboard  114  can be arranged to receive a discrete input at each keypad using a finger motion referred to as a keystroke. In the described embodiment, the symbols on each key pad can be laser etched thereby creating an extremely clean and durable imprint that will not fade under the constant application of keystrokes over the life of portable computing device  100 . In order to reduce component count, a keycap assembly can be re-provisioned as a power button. For example, key pad  118 - 1  can be used as power button  118 - 1 . In this way, the overall number of components in portable computing device  100  can be commensurably reduced. 
     Track pad  116  can be configured to receive finger gesturing. A finger gesture can include touch events from more than one finger applied in unison. The gesture can also include a single finger touch event such as a swipe or a tap. The gesture can be sensed by a sensing circuit in track pad  116  and converted to electrical signals that are passed to a processing unit for evaluation. In this way, portable computing device  100  can be at least partially controlled by touch. 
     Lid portion  108  can be moved with the aid of clutch assembly  110  from the closed position to remain in the open position and back again. Lid portion  108  can include display  120  and rear cover  122  (shown more clearly in  FIG. 2 ) that can add a cosmetic finish to lid portion  108  and also provide structural support to at least display  120 . In the described embodiment, lid portion  108  can include mask (also referred to as display trim)  124  that surrounds display  120 . Display trim  124  can be formed of an opaque material such as ink deposited on top of or within a protective layer of display  120 . Display trim  124  can enhance the overall appearance of display  120  by hiding operational and structural components as well as focusing attention onto the active area of display  120 . 
     Display  120  can display visual content such as a graphical user interface, still images such as photos as well as video media items such as movies. Display  120  can display images using any appropriate technology such as a liquid crystal display (LCD), OLED, etc. Portable computing device  100  can also include image capture device  126  located on a transparent portion of display trim  124 . Image capture device  126  can be configured to capture both still and video images. Lid portion  108  can be formed to have uni-body construction that can provide additional strength and resiliency to lid portion  108  which is particularly important due to the stresses caused by repeated opening and closing. In addition to the increase in strength and resiliency, the uni-body construction of lid portion  108  can reduce overall part count by eliminating separate support features. 
     Data ports  128 - 132  can be used to transfer data and/or power between an external circuit(s) and portable computing device  100 . Data ports  128 - 132  can include, for example, input slot  128  that can be used to accept a memory card (such as a FLASH memory card), data ports  130  and  132  can be used to accommodate data connections such as USB, FireWire, Thunderbolt, and so on. In some embodiments, speaker grid  134  can be used to port audio from an associated audio component enclosed within base portion  102 . 
       FIG. 2  shows portable computing device  100  in a closed (lid) configuration that shows rear cover  122  and logo  202 . In one embodiment, logo  202  can be illuminated by light from display  120 . It should be noted that in the closed configuration, lid portion  108  and base portion  102  form what appears to be a uniform structure having a continuously varying and coherent shape that enhances both the look and feel of portable computing device  100 . 
       FIG. 3  shows another embodiment in the form of portable computing device  300  that is smaller than portable computing device  100 . Since portable computing device  300  is smaller in size than portable computing device  100 , certain features shown in  FIG. 1  are modified, or in some cases lacking, in portable computing device  300 . For example, base portion  302  can be reduced in size such that separate speakers (such as speaker grid  134 ) are replaced with an audio port embodied as part of keyboard  114 . However, bottom case  304  and top case  306  can retain many of the features described with regards to portable computing device  100  (such as display  120  though reduced to an appropriate size). 
       FIG. 4  shows an external view of bottom case  104  showing relative positioning of support feet  402 , inset  112 , cosmetic wall  404  that can be used to conceal clutch assembly  110  and fasteners  406  used to secure bottom case  104  and top case  106  together. Support feet  402  can be formed of wear resistant and resilient material such as plastic. Also in view are multi-purpose front side sequentially placed vents  408  and  410  that can be used to provide a flow of outside air that can be used to cool internal components. In the described embodiment, vents  408  and  410  can be placed on an underside of top cover  106  in order to hide the vents from view as well as obscure the view of an interior of portable computing device  100  from the outside. Vents  408  and  410  can act as a secondary air intake subordinate to primary air intake vents located at a rear portion of portable computing device  100  (described below). In this way, vents  408  and  410  can help to maintain an adequate supply of cool air in those situations where portions of the rear vents are blocked or otherwise have their air intake restricted. 
     Vents  408  and  410  can also be used to output audio signals in the form of sound generated by an audio module (not shown). In one embodiment, a selected portion (such as portions  412  and  414 ) can be used to output sound at a selected frequency range in order to improve quality of an audio presentation by portable computing device  100 . Vents  408  and  410  can be part of an integrated support system in that vents  408  and  410  can be machined from the outside and cut from the inside during fabrication of top case  106 . As part of the machining of vents  408  and  410 , stiffener ribs can be placed within vent openings  408  and  410  to provide additional structural support for portable computing device  100 . 
     Moreover, trusses  418  can be formed between vents  408  and  410  in combination with stiffener ribs to add both structural support as well as assist in defining both the cadence and size of vents  408  and  410 . The cadence and size of vents  408  and  410  can be used to control air flow into portable computing device  100  as well as emission of RF energy in the form of EMI from portable computing device  100 . Accordingly, stiffener ribs can separate an area within vents  408  and  410  to produce an aperture sized to prevent passage of RF energy. The size of an aperture can restrict the emission of RF energy having a wavelength that can be “trapped” by the aperture. In this case, the size of vents  408  and  410  is such that a substantial portion of RF energy emitted by internal components can be trapped within portable computing device  100 . Furthermore, by placing vents  408  and  410  at a downward facing surface of top case  106 , the aesthetics of portable computing device  100  can be enhanced since views of internal components from an external observer are suppressed. 
       FIG. 5  shows integrated support system in accordance with the described embodiments. In order to enhance the structural integrity, reduce bowing, and improve resistance to infrequent but potentially damaging events such as being dropped, top case  106  can be fabricated to include integrated support system  700 . Generally speaking, top case  106  can be divided into various structural zones each of which can be expected to be exposed to various amounts and types of stress. For example, top case  106  can divided into palm rest zone  702 , track pad zone  704 , side vents zone  706 , rear vent zone  708 , clutch bolt zone  710 , and keyboard zone  712  that can each have individual structures that tie in together in a floor-to-ceiling arrangement to form integrated support system  700 . (It should be noted that by integrated it is meant that there are substantially no breaks or gaps in the structural elements that form integrated support system  700 .) For example, keyboard zone  712  can include keyboard support rib  714  that racetracks about keyboard zone  712 . Keyboard support rib  714  can have an enhanced thickness “t” in order to provide a substantially increased resistance to flexing or bending (that is proportional to t 3 ). By interconnecting the various structural elements of integrated support system  700 , any stress or other load applied at a particular point in a specific zone can be more evenly distributed within top case  106  thereby reducing the likelihood of bowing or warping top case  106 . 
     In addition to providing stress distribution about the perimeter of top case  106 , structural elements of integrated support system  700  can span top case  106  in a “crisscross” pattern obviating the problems of flexing due to what can be referred to as a “trampoline” effect, in which a central portion of top case  106  flexes more than does the edge regions (along the lines of a trampoline). In this way, portable computing device  100  can respond to physical impacts and externally applied stress as an integrated whole in contrast to conventionally configured portable computing devices where internal components are discretely attached to a housing with little or no cross support. In this way, the framing of top case  106  in the form of integrated support system  700  can flow from wall to wall and edge to edge and structural member to structural member 
       FIG. 6  shows a view of top case  106  highlighting the relationship between integrated support system  700  and various structural components in accordance with the described embodiment. More particularly,  FIG. 6  shows an interior view of top case  106  illustrating various openings used to accommodate keyboard  114  and track pad  116 . More specifically, keyboard openings  722  can each have a size and shape in accordance with an associated key cap assembly. For example, opening  722 - 1  can be sized to accommodate power button  118 - 1  whereas opening  722 - 2  can be sized to accommodate a space bar. In addition to keyboard openings  722 , opening  724  can accommodate track pad  116 . For example, track pad  116  can be attached directly to top case  106  at shoulders  726  and flex support  727  can be used to provide support for a flex connector. Furthermore, a dome switch associated with track pad  116  can be supported at support plate  728 . 
     Top case  106  can be fabricated in such a way that integrated support system  700  (as shown by the broken line) can be used to provide support for internal components as well as a mechanism for distributing loads more evenly about top case  106  thereby avoiding localized stress points. In this way, the likelihood of warping or bowing of top case  106  can be substantially reduced. In addition to providing for load distribution, integrated support system  700  can provide support points and structures for various internal components. For example, as described above, stiffener ribs can be integrally formed with integrated support system  700  in such a way that an external load applied to portable computing device  100  in the vicinity of vents  410  (or  408 ) can be passed by way of stiffener ribs to integrated support system  700 . In this way, the load can be transferred away from the point where the load is applied and distributed more evenly about top case  106  and bottom case  104  thereby reducing the possibility of warping or bowing. 
     As part of integrated support system  700 , magnetic clamp supports  732  can provide a support structure for magnet pad  734  used to support magnets that magnetically attach top case  106  and bottom case  104  together that facilitates the insertion of and securing of fasteners  406  into bosses  736 . For example, during an assembly operation, top case  106  and bottom case  104  are first magnetically attached to each other using magnets secured to magnet pad  734 . The magnetic attraction is such that sufficient “play” in (x,y) is available for securing fasteners  406  into bosses  736  affording an easier and more timely assembly operation. Moreover, by securing top case  106  and bottom case  104  in a central region, an amount of flexion of bottom case  104  is substantially reduced thereby preventing “belly rub” where an exterior surface of bottom case  104  flexes to the point where it comes in contact with a surface upon which it rests. Other mounting features can include audio jack mounts  738 , microphone mounts  739 , and clutch assembly support plates  740  for securing clutch assembly  110  to top case  106 . 
     Magnetic attachment plates  742  can be used to form a magnetic circuit with magnets disposed within lid portion  108  for securing lid portion  108  to base portion  102  in the closed configuration of portable computing device  100 . Rear vent openings  744  can be used to provide air for cooling internal components such as a CPU, GPU and so forth. In one embodiment, left and right vent openings  744 - 1  can be used to direct exhaust air away from portable computing device  100  whereas central vent openings  744 - 2  can be used to direct cooler intake air into portable computing device  100 . In addition to vent openings  744 , vent openings  408  and  410  can be used as a secondary source of cool intake air in situations in which vent openings  744 - 2  are partially or fully blocked to assure adequate cooling of various internal components. Keyboard support rib  714  can be used to support a keyboard feature plate as well as part of an EMI shield used to block RF energy and a light block used to block extraneous light emanating from a light source used to illuminate key pads  118 . 
     Returning to the track pad  116 , one possible configuration is illustrated in  FIG. 7 . As illustrated, the track pad  116  may include a cover  802  which may define an outer surface with which a user may interact by inputting gestures thereon. The cover  802  may comprise glass in some embodiments. The gestures may be detected by a touch sensor  804 , which may be coupled to the bottom of the cover  802 , as illustrated. In some embodiments the touch sensor  804  may comprise a plastic material such polyethylene terephthalate (PET). 
     The track pad  116  may also include a printed circuit board (PCB)  806  including one or more touch circuits  808  and connectors  810  thereon, and associated communications medium  811  coupled thereto. The touch sensor  804  may be positioned between the printed circuit board  806  and the cover  802 . The printed circuit board  806  may be in communication with the touch sensor  804  such that that the printed circuit board  806  receives signals therefrom. 
     The cover  802  may extend from a first end  812  to a second end  814 . The first end  812  of the cover  802  may be pivotally coupled to the top case  106  of the portable computing device  100 . In particular, mounting points  816  may be configured to couple to the shoulders  726  of the top case  106  such that the track pad  116  is received in the opening  724  (see, e.g.,  FIG. 6 ). 
     Whereas the first end  812  of the cover  802  may be pivotably coupled to the top case  106 , the second end  814  of the cover may be decoupled from the case. Thereby, the second end  814  of the cover  802  may pivot. In this regard, the track pad  116  may further comprise a dome switch  818  (or other embodiment of a switch) positioned proximate the second end  814  of the cover  802 . The dome switch  818  may be coupled to the touch sensor  804 . Accordingly, as the second end  814  of the cover  802  pivots, the dome switch  818  may be activated. Thus, user inputs may also be inputted through the track pad  116  through pivoting the cover  802  to actuate the dome switch  818 . 
     As further illustrated in  FIG. 7 , acoustic transmission members  821  are coupled to the track pad  116  near, proximate, and/or adjacent the first end  812 . In this manner, when pivoting the assembly as described above, audible sounds produced through the inversion and subsequent reformation of the dome switch  818  may be coupled to an interior of an assembled portable computing device  100 / 300  through the acoustic transmission members  821 . For example, the acoustic transmission members  821  may be formed of semi-closed cell acoustic foam according to some implementations. The acoustic foam may therefore guide acoustic energy therethrough, away from a user of the track pad  116  and towards an interior of the device  100 / 300  during pivoting (e.g., clicking) 
     However, due to the second end  814  of the cover  802  being decoupled from the top case  106 , it may be desirable to stiffen and support the second end to reduce other undesirable effects besides acoustic dampening. In this regard, the printed circuit board  806  (and additional intervening standoffs  861  illustrated in  FIG. 8 ) may function as a stiffener configured to support the second end  814  of the cover  802 . In this regard, the printed circuit board  806  and/or standoffs  861  may also define one or more protrusions  822  that extend past the second end  814  of the cover  802 , and which are configured to engage recesses  748  in the top case  106  (cf.  FIG. 6 ). Further, in addition to the touch circuits  808  and connectors  810 , the dome switch  818  may be coupled through a hole or recess  819  of the printed circuit board  806 . 
     Coupling of the dome switch  818  through the printed circuit board  806  may offer increased durability as compared to other implementations. For example, as the track pad  116  is pivotally attached to the top case  106 , and as the dome switch  818  provides a compliance for activation of the pivoting assembly (e.g., through clicking), coupling through the printed circuit board  806  reduces “swiping” or x-y translation during pivoting due to shorter arc-lengths of pivoting travel, which may increase a useable lifetime of the dome switch  818  and therefore the entire track pad  116 . For example, according to experimental results conducted in accordance with this particular implementation, more than about five million click or pivot cycles are possible through coupling of the dome switch through the printed circuit board  806 . 
     Turning now to  FIG. 8 , an exploded view of the track pad  116  is presented which further illustrates its benefits. 
     As shown, the track pad  116  includes the cover or glass  802 . The track pad  116  further includes member  803  (optional) arranged between the cover  802  and the touch sensor  804 . The member  803  may be a compliance member, adhesive film, polymer film, or any other suitable member. The track pad  116  further includes a grounding film or substantially planar ground potential member  805  arranged on the touch sensor  804 . The ground film  805  may provide a reference ground potential for detecting user inputs through the touch sensor  804 . In some embodiments, the ground film  805  and touch sensor  804  are integrally arranged as a single unit and may not be illustrated as separate. 
     The track pad  116  further includes dome switch  818  arranged within hole  819  of the printed circuit board  806  and the ground film  805 , and coupled to the touch sensor  804 . In this regard, a dome or flexible portion of the dome switch  816  may be arranged to be activated through the hole  819 , while being directly coupled to the touch sensor  804 . Thus, an additional member  1100  (e.g., set screw or screw-like support member) illustrated in  FIG. 11  is provided to allow engagement of the dome switch  818  through the hole  819 . 
     The track pad  116  in  FIG. 8  further includes standoff members  861  arranged on the ground film  805 . The standoff members  861  may be members configured to add a vertical differential between the printed circuit board  806  and the ground film  805 . In some embodiments, the standoff members  861  may be formed directly from the printed circuit board  806 , for example, through additional laminations, and allow for the dome switch to be situated beneath the printed circuit board  806 . 
     The track pad  116  further includes compound mounting points or support members  816  arranged on the ground film  805 . As illustrated, intervening compliance members or standoffs may be included to protect the ground film  805 . 
     As further illustrated in  FIG. 9 , in some embodiments a backing plate  750  may be positioned below the track pad  116 . The backing plate  750  may be configured to define a planar surface  752  which may form a portion of a compartment in which a mass storage device  754  (e.g., a hard drive or solid state memory) is positioned. In this regard, the planar surface  752  of the backing plate  750  may abut an elastomeric material coupled to the mass storage device  754 . Further, the printed circuit board  806  may comprise one or more protrusions  822  that extend past the second end  814  of the cover  802 . As illustrated, the protrusions  822  may be configured to engage recesses  748  defined in the outer case  106  proximate the opening  724  therein. Accordingly, the protrusions  822  may prevent the track pad  116  from extending out of the opening  724  in the top case  106 . As further illustrated, the touch sensor  804  may extend past the second end  814  of the cover  802  and past the protrusions  822  such that a gap  824  between the cover and the top case  106  may be concealed. In this regard, the touch sensor  804  may define a relatively dark color, such as black, which conceals the gap  824  and other components in the personal computing device  100 . 
     Turning now to  FIG. 10 , an expanded view of the acoustic transmission members  821  is provided. As shown, the acoustic transmission members  821  are coupled between the track pad  116  and the top case  106  such that audible noise produced at the dome switch  818  is transmitted away from a user of the device  100 / 300  and into an interior cavity thereof. Therein the cavity, the acoustic noise may be dissipated through interaction with a plurality of interior components. It should be understood that the acoustic transmission members  821  may also function to dampen the audible noise, and may provide other functions not explicitly described herein. 
     As described above, the track pad  116  may be pivotally coupled to top case  106  through members  816 . Furthermore, dome switch  818  may provide a compliance feature allowing for clicking and/or pivoting of the entire assembly. As illustrated in  FIG. 11 , a set screw or support member  1100  may be arranged through the hole  819  of the printed circuit board  806  thereby allowing inflection of the dome switch assembly  818 . The set screw  1100  may be set within support plate  728  on top cover  106  during assembly of the device  100 / 300 . 
     A related method for assembling a track pad  116  and/or device  100 / 300  is also provided. As illustrated in  FIG. 12 , the method  900  may include providing a cover extending from a first end to a second end, providing a touch sensor, providing a dome switch, and providing a printed circuit board with an opening or hole at operation  901 . The method may further comprise coupling the touch sensor to the cover and coupling the dome switch to the touch sensor at operation  902 . Further, the method may include coupling the printed circuit board to the second end of the cover to support the second end of the cover and coupling the printed circuit board to the touch sensor at operation  904 . 
     In some embodiments the method may also include pivotally coupling the first end of the cover to a case of a portable computing device with the second end decoupled from the case. The method may also include concealing a gap between the cover and the case by extending the touch sensor past one or more protrusions defined by the printed circuit board at the first end of the cover. 
     Turning now to  FIG. 13 , a cross sectional view of dome switch  818  and support plate  728  arranged in a fixture to calibrate set screw  1100  position. In one embodiment, the position of set screw  1100  can provide good functionality for the actuation of the dome switch  818 , and control audible acoustic properties related to the actuation of dome switch  818 . For example, if set screw is too far into support plate  728 , partial actuation of the dome switch  818  can occur. Conversely, if set screw  1100  is too far from dome switch, undesired acoustic noises may be produced, or set screw  1100  may be actuated incorrectly. 
     To help ensure precise positioning of set screw  1100 , a gauge fixture  1302  acting as a gauge block can be inserted into support plate  728  as shown. Dimensions of gauge fixture  1302  can be well controlled and can be precisely measured prior to use. On an upper portion of gauge fixture  1302 , a collar  1304  can be formed to guide and position set screw  1100 . 
     An optical measuring device  1310  can measure and determine a distance from the measuring device  1310  to set screw  1100 . In another embodiment, optical measure device  1310  can determine a distance from the measuring device to a driver bit or other tool used to attach or drive set screw  1100  into support plate  728 . When this measurement is made, the optical measuring device is also measuring the additional distance attributable to the gauge fixture  1302 . This measurement can be used to provide a preferred distance that the set screw  1100  should be positioned with respect to support plate  728 . After that distance is determined, the gauge fixture  1302  can be removed, the correct distance calculated (by subtracting the distance attributable to the gauge fixture  1302 ) and the set screw  1100  correctly positioned in support plate  728 . In one embodiment, the optical measuring device can again measure to the top of set screw  1100  or driver bit. The collar  1304  can advantageously position and hold set screw  1100  in place while measurements are being made when gauge fixture  1302  is placed in support plate  728 . In one embodiment, collar  1304  can constrain any motion from set screw  1100 . 
     Ground tabs can be attached to ground film  805  that is in turn bonded to touch sensor  804 . The ground tabs can couple ground film  805  to printed circuit board  806 . Ground tabs are typically bonded to the printed circuit board  806  with a high temperature bonding process. In order to avoid exposing touch sensor  804 , ground file  805  and other track pad components to heat, a service loop can be provided through the ground tab.  FIGS. 14A-14F  illustrate steps for controllably forming a service loop in the ground tabs.  FIG. 14A  shows a simplified diagram  1400  of ground film  805  and ground tabs  1402 . Ground tabs  1402  can be attached to ground film  805  with conductive adhesives  1404  or any other technically feasible method. For example, ground tabs  1402  can be attached to ground film  805  with anisotropic conductive film adhesives. 
     In a first step shown in  FIG. 14A , the ground tabs  1402  can be arranged to form an angle with respect to ground film  805 .  FIG. 14B  shows a bending step. Accordingly, in  FIG. 14B  the second end of the ground tab  1402  is bent by partially rolling the second end of the ground tab over the ground film  805 .  FIG. 14B  also shows that bending the ground tab  1402  may include pushing a first press  1420  in the direction of the arrow (cf.  FIG. 14B ). The first press  1420  may have an angled point  1422  to lift the second end of the ground tab  1402  to a first position. 
       FIG. 14C  shows a step of pushing a second press  1425  against the second end of the ground tab  1402  from the first position to a position forming the acute angle, in the direction shown by the arrow (cf.  FIG. 14C ). In some embodiments, the acute angle is 45 degrees. Accordingly, the second press  1425  having a cutout  1427  in the shape of the acute angle presses the second end of the ground tab  1402  against a fixture  1430 . The fixture  1430  has an edge formed in the acute angle. In some embodiments, the steps shown in  FIG. 14C ,  FIG. 14D , and  FIG. 14E  are performed with the fixture  1430  in place, as shown. 
       FIG. 14D  shows ground tab  1402  arranged to form an acute angle with respect to ground film  805 . In a second step, the printed circuit board  806  can be bonded to ground tab  1402 . This step is illustrated in  FIG. 14E . In some embodiments, fixture  1430  thermally isolates a contact point of the printed circuit board  806  with the ground tab  1402  from the first end of the ground tab proximal to the ground film  805 . The step shown in  FIG. 14E  may include arranging the printed circuit board  806  to contact the ground tab  1402  by pressing the second end of the ground tab to the printed circuit board  806  over the fixture  1430 . Since printed circuit board  806  is disposed away from ground film  805 , any heat used during the bonding process is also away from ground film  805 . This can protect elements near and around ground film  805  from exposure to extremes in heat. In particular, in some embodiments steps  14 D and  14 E prevent the formation of air or gas bubbles in adhesive portions included in and proximal to ground film  805 . The appearance of air bubbles is undesirable, since air bubbles tend to change in size over time, thereby altering the calibration settings of a touch sensor proximal to ground film  805 . 
     After the bond between ground tab  1402  and printed circuit board  806  has set, the printed circuit board  806  can be positioned against adhesive  1404  and ground film  805 . This is shown in  FIG. 14F . In one embodiment, the printed circuit board  806  is positioned against adhesive  1404  and ground film  805  only after the temperature of the printed circuit board  806 , and more particularly the interface between printed circuit board  806  and ground tabs  1402  have cooled at a temperature that will not cause damage to ground film  805 , adhesive  1404  or the surrounding area. This method can enable shorter ground tabs  1402  by virtue of positioning the printed circuit board  806  at an acute angle. The shorter ground tabs  1402  can be easier to dress within the portable computing device.  100 .  FIG. 15  is an isometric view of printed circuit board  806  positioned over ground film  805  with ground tabs  1402 . The ground tabs  1402  can be coupled to printed circuit board  806  in such a manner that can allow relatively small loops  1502  to be formed. 
     Although the foregoing disclosure has been described in detail by way of illustration and example for purposes of clarity and understanding, it will be recognized that the above described disclosure may be embodied in numerous other specific variations and embodiments without departing from the spirit or essential characteristics of the disclosure. Certain changes and modifications may be practiced, and it is understood that the disclosure is not to be limited by the foregoing details, but rather is to be defined by the scope of the appended claims.

Metadata:
Filing Date: 20130402
Publication Date: 20150512
Grant Date: 20150512
Priority Date: 20121018
Inventors: LEGGETT WILLIAM F.
ROCKFORD DAVID M.
REID GAVIN J.
CASEBOLT MATTHEW P.
JANG CHANGSOO
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F3/03547", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/182", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/32", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H9/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49149", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49105", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/169", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H9/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/03547", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/169", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K3/32", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/182", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H11/00", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 50485113