PATENT DOCUMENT

Publication Number: US-9304550-B1
Application Number: US-201414500948-A
Country: US
Kind Code: B1

Title: Adhesive bond with integrated release mechanism

Abstract:
This application relates to methods and apparatus relating to an adhesive bond that includes an integrated release mechanism. The adhesive bond can secure components in a portable electronic device, such as a battery, to the housing of the portable electronic device. The release mechanism can be embodied as a thin layer of polymeric material sandwiched between a first adhesive layer and a second adhesive layer. The first and second adhesive layers are joined to one another by a number of pillars that extend through openings in the release mechanism. A portion of the release mechanism can protrude from the adhesive bond allowing a technician or user to pull the release mechanism out of the adhesive bond, which severs the pillars that hold the adhesive layers together. In this way, the release mechanism allows for efficient separation of the adhesively secured components.

Claims:
What is claimed is: 
     
       1. An adhesive bond for joining a first component to a second component, the adhesive bond comprising:
 a first adhesive layer; 
 a second adhesive layer; 
 a release mechanism disposed between the first and second adhesive layers, the release mechanism defining a plurality of openings; 
 a liner that separates the release mechanism from the first and second adhesive layers; and 
 a plurality of pillars adhesively coupled with both the first adhesive layer and the second adhesive layer, each of the pillars passing through a corresponding opening of the release mechanism. 
 
     
     
       2. The adhesive bond as recited in  claim 1 , wherein the release mechanism comprises a die-cut polymeric sheet. 
     
     
       3. The adhesive bond as recited in  claim 2 , wherein the release mechanism extends from one end of the adhesive bond. 
     
     
       4. The adhesive bond as recited in  claim 3 , wherein the release mechanism is configured to cut through the plurality of pillars when the release mechanism is pulled out from between the first and second adhesive layers. 
     
     
       5. The adhesive bond as recited in  claim 4 , wherein the plurality of pillars are formed from foam. 
     
     
       6. The adhesive bond as recited in  claim 1 , wherein the plurality of openings are configured to sequentially engage the pillars as the release mechanism is being removed from the adhesive bond. 
     
     
       7. The adhesive bond as recited in  claim 1 , wherein the first adhesive layer is configured to bond with the first component and the second adhesive layer is configured to bond with the second component; and the first component is a battery cell and the second component is a portable computer device housing. 
     
     
       8. The adhesive bond as recited in  claim 1 , wherein the liners substantially prevents all contact between the release mechanism and at least one of the first adhesive layer and the second adhesive layer. 
     
     
       9. The adhesive bond as recited in  claim 1 , wherein the first and second adhesive layers each comprise:
 one or more adhesion layers; and 
 one or more non-adhesion layers alternating with the one or more adhesion layers. 
 
     
     
       10. The adhesive bond as recited in  claim 1 , wherein the first and second adhesive layers each comprise double-sided tape. 
     
     
       11. The adhesive bond as recited in  claim 1 , wherein a portion of the release mechanism that defines each of the plurality of openings is sharpened. 
     
     
       12. An adhesive bond for joining a first component to a second component, the adhesive bond comprising:
 a first pressure sensitive adhesive (PSA) layer; 
 a second PSA layer; 
 a release mechanism comprising a polymeric sheet at least partially disposed between the first and second PSA layers, the polymeric sheet defines a plurality of die-cut openings; 
 a liner that separates the release mechanism from the first and second PSA layers and includes openings corresponding to the openings defined by the polymeric sheet; and 
 a plurality of foam pillars, each of the foam pillars being adhesively coupled with both the first PSA layer and the second PSA layer and passing through a corresponding die-cut opening defined by the polymeric sheet, 
 wherein the release mechanism is shaped to minimize an amount of force required to cut through the plurality of pillars when the release mechanism is pulled out from between the first and second PSA layers. 
 
     
     
       13. The adhesive bond as recited in  claim 12 , wherein the plurality of die-cut openings are defined by sharpened edges formed by a coining operation. 
     
     
       14. The adhesive bond as recited in  claim 13 , wherein each of the plurality of pillars has a shape and size in accordance with a corresponding one of the plurality of die-cut openings. 
     
     
       15. The adhesive bond as recited in  claim 13 , wherein the sharpened edges defining the plurality of openings are configured to sequentially engage the pillars as the release mechanism is being removed from the adhesive bond. 
     
     
       16. The adhesive bond as recited in  claim 15 , wherein the plurality of openings comprise elongated rounded slots, circles, ovals, or square slots. 
     
     
       17. A portable electronic device, comprising:
 a first housing component; 
 a second housing component that cooperates with the first housing component to define an interior volume; 
 an internal component housed inside the interior volume and joined to the first housing component via an adhesive bond, the adhesive bond comprising:
 a first adhesive layer; 
 a second adhesive layer; 
 a release mechanism disposed between the first and second adhesive layers, the release mechanism defining a plurality of openings; 
 a liner comprising a first layer adhered to the first adhesive layer and a second layer adhered to the second adhesive layer that separates the release mechanism from the first and second adhesive layers; and 
 a plurality of pillars adhesively coupled with both the first adhesive layer and the second adhesive layer, each of the pillars passing through a corresponding opening of the release mechanism. 
 
 
     
     
       18. The portable electronic device as recited in  claim 17 , wherein the internal component is a battery cell. 
     
     
       19. The portable electronic device of  claim 17 , wherein the portable electronic device comprises a laptop computer. 
     
     
       20. The portable electronic device of  claim 17 , wherein the release mechanism extends from at least one end of the adhesive bond allowing a technician to apply a force operable to cut through the plurality of pillars.

Description:
FIELD 
     The described embodiments relate generally to adhesively securing components. More particularly, the present embodiments relate to methods and apparatus for forming an adhesive bond between electrical components that can be easily severed to allow replacement or repair of the components. 
     BACKGROUND 
     Portable electronic devices such as laptops and cellular telephones often contain components that are adhesively secured to each other. For example, a battery may be adhesively secured to an enclosure of the portable electronic device. However, adhesively secured components can be particularly difficult to separate, requiring specialized equipment and/or specialized skill. For example, a Kevlar® thread might be employed to sever the adhesive bond between the battery and the enclosure. Unfortunately, specialized removal tools of this type can be expensive and require specialized support equipment and training to use them. In some cases, specialized removal tools can cause damage to the components in the form of dents, scratches, and/or deformation of the housing components to an extent where the housing components require replacement or at a minimum, time-consuming and/or costly rework. Moreover, environmental regulations and laws in some countries may require that a battery be removable without the use of specialized removal tools. 
     SUMMARY 
     This paper describes various embodiments that relate to a releasably adhesive bond for joining a first component to a second component. 
     An adhesive bond is disclosed that can include a first adhesive layer and a second adhesive layer. A release mechanism can be positioned between the first and the second adhesive layers. Further, the release mechanism may define a number of openings. The adhesive bond may also include a liner positioned between the release mechanism and the adhesive layers that prevents the release mechanism from binding to the first and the second adhesive layers. A number of pillars may be adhesively coupled with both the first adhesive layer and the second adhesive layer. Each of the pillars may pass through a corresponding opening defined by the release mechanism. 
     An adhesive bond that joins a first component to a second component is disclosed. The adhesive bond may include a first layer of adhesive tape and a second layer of adhesive tape. In some embodiments, the first and second layers of adhesive tape can be pressure sensitive adhesive. The adhesive bond can also include a release mechanism made from a polymeric sheet. The polymeric sheet can be located between the first and the second PSA layers. The polymeric sheet can define a number of openings. The openings may be manufactured using a die-cutting technique also known as coining. The adhesive bond may also include a liner for separating the release mechanism from the first and the second layers of adhesive tape. A number of foam pillars may be adhesively coupled with both the first layer of adhesive tape and the second layer of adhesive tape. Each of the pillars may pass through a corresponding opening of the release mechanism. The release mechanism can be shaped to minimize the amount of force required to shear through the pillars as the release mechanism is being pulled out from between the first and second layers of adhesive tape. 
     A portable electronic device is disclosed that has a first housing part and a second housing part that together define an internal volume. An internal component is housed within the internal volume and joined to the first housing part by an adhesive bond. The adhesive bond may include a first adhesive layer and a second adhesive layer. A release mechanism may be located between the first and the second adhesive layers. Further, the release mechanism may define a number of openings. The adhesive bond may also include a liner for separating the release mechanism from the first and the second adhesive layers. The liner can include two polymeric sheets that are adhered to both the first adhesive layer and the second adhesive layer. A number of pillars may be adhesively coupled with both the first adhesive layer and the second adhesive layer. Each of the pillars may pass through one of the openings defined by the release mechanism. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
    
    
     
       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: 
         FIGS. 1A-1B  show perspective views of an illustrative electronic device having components attached to each other using an adhesive bond; 
         FIG. 2  shows a top view of a number of batteries adhesively coupled to a housing component of the illustrative electronic device; 
         FIG. 3A  shows a cross-sectional side view of a number of layers that form an adhesive bond; 
         FIG. 3B  shows a cross-sectional top view of a release mechanism of the adhesive bond; 
         FIGS. 3C-3E  show a number of cross-sectional side views of the adhesive bond while the release mechanism shears through the pillars joining the adhesive bond together; 
         FIGS. 4A-4B  show cross-sectional side views of a number of layers of various alternative adhesive bond embodiments; 
         FIG. 5A  shows a cross-sectional side view of another embodiment of the adhesive bond in which edges defining openings in the release mechanism have been sharpened by a coining process; 
         FIG. 5B  shows a perspective view of a specific implementation of an adhesive bond in which the release mechanism has been formed by a coining operation; 
         FIG. 6A  shows a cross-sectional top view of the release mechanism in which the openings defined by the release mechanism have a staggered configuration; 
         FIGS. 6B-6E  show cross-sectional top views of the release mechanism depicted in  FIG. 6A  while the release mechanism is used to release the adhesive bond; and 
         FIG. 7  shows a flow diagram representing a method for forming the adhesive bond. 
     
    
    
     DETAILED DESCRIPTION 
     Representative applications of methods and apparatus according to the present application are described 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 described embodiments may 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 described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     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 the 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. 
     Existing methods of adhesively securing components generally result in the secured components being particularly difficult to separate. In many cases, separating adhesively joined components can cause damage to at least one of the joined components; in some cases, the damage may be severe enough to prevent reuse of the damaged component. More specifically, in the case where at least one of the adhesively joined components is a battery cell stack, damaging even one battery cell of the many battery cells disposed within the battery cell stack could potentially release hazardous materials into the environment and/or cause injury. One way to reduce the likelihood of damaging the joined components is to utilize, a specialized removal tool. For example, the specialized removal tool can take the form of a Kevlar thread that can be employed to sever the adhesive bond between the battery cell stack and an enclosure. The use of other specialized removal tools is also possible. For example, the specialized tool can alternatively take the form of a wedge that can be inserted between the components, thereby allowing a mechanical advantage to be applied at the interface between the components sufficient to sever the adhesive bond. Unfortunately, the aforementioned specialized removal tools can be expensive and difficult to operate. Furthermore, in some embodiments, use of the specialized removal tools can cause dents, scratches, and/or deformation of the components to an extent where the components require replacement or at minimum time-consuming or costly rework. Moreover, environmental regulations and laws in some countries may require that a battery be user-removable. 
     One solution to this issue is to integrate a release mechanism into an adhesive bond. The release mechanism can be embodied as a thin layer or sheet of material positioned between two adhesive bonding layers. The adhesive bonding layers can be joined to one another by way of a number of pillars that extend through openings defined by the release mechanism. A portion of the release mechanism can protrude from the adhesive bond to allow a technician or user wishing to sever the adhesive bond to pull upon the protruding portion of the release mechanism until the edges defining the openings of the release mechanism to shear completely through the pillars. The release mechanism can be prevented from sticking or binding to the adhesive bonding layers by a liner made up of at least two non-adhesive layers that mask adhesive surfaces of the adhesive layers oriented towards the release mechanism. In some embodiments, the pillars can separate the adhesive bonding layers far enough apart to prevent the release mechanism from being compressed between the non-adhesive layers. In this way, frictional binding between the release mechanism and the non-adhesive layers can be substantially prevented. 
     In some embodiments, the non-adhesive layers are made of a resin based film, along the lines of polyethylene terephthalate (PET). The release mechanism can be referred to as a floating cutting layer and can also be made from PET. In some embodiments, the pillars, the release mechanism, or both the pillars and the release mechanism can be shaped and/or arranged to minimize the force needed for the edges defining the openings in the release mechanism to shear through the pillars. The edges of the release mechanism can be sharpened during a die-cutting operation so that when the release mechanism is pulled the pulling force can be concentrated at the sharpened or shaped edges, thereby reducing an amount of force required to shear through the pillars and sever the adhesive bond. In some embodiments, the openings of the release mechanism may be arranged or offset at varying distances from the pillars so that each of the pillars are engaged sequentially, thereby reducing a magnitude of the force necessary to sever the adhesive bond. 
     These and other embodiments are discussed below with reference to  FIGS. 1A-7 ; 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. 1A  shows a perspective view of exemplary electronic device  100  suitable for use with the described embodiments. In some embodiments, electronic device  100  can be a portable electronic device along the lines of a laptop computer. Electronic device  100  includes one housing component that takes the form of base  102  pivotally coupled to lid  104  by hinge assembly  106 . Lid  104  can include a number of electrical components that include at least circuitry for supporting display assembly  108 . Base  102  can include a number of user interface components such as keyboard  110  and track pad  112 , which can allow a user to interact with electronic device  100 .  FIG. 1B  shows a perspective view of a bottom portion of electronic device  100 . In particular, a housing component taking the form of bottom cover  114  is depicted, which is operable to close an opening leading into base  102 . In this way, bottom cover  114  and base  102  cooperate to define an internal volume within which internal components can be positioned and protected. Bottom cover  114  is depicted taking the form of a substantially flat bottom cover. However, bottom cover can also have other geometries along the lines of a curved geometry, in which case bottom cover  114  may only contact base  102  along a periphery of base  102 . 
       FIG. 2  shows an interior view of base  102 . Batteries  202  can be adhesively coupled to base  102  by a number of adhesive bonds. At least one release mechanism  204  is embedded within each of the adhesive bonds that couple batteries  202  to base  102 .  FIG. 2  depicts a portion of a number of release mechanisms  204  that protrude from beneath batteries  202 . The portion of release mechanism  204  that protrudes from the adhesive bond can allow a technician or user wishing to sever the adhesive bond to actuate the release mechanism by pulling on the protruding portion of release mechanism  204  until the release mechanism pulls free from the adhesive bond. Removal of release mechanism  204  from between batteries  202  and base  102  in this manner completely severs the adhesive bond. While only a small portion of release mechanism  204  is shown extending from beneath battery  202 , it should be understood that a greater length of material can extend from beneath battery  202  and in some embodiments the length of material extending from beneath battery  202  can include a feature such as a loop or handhold to make gripping release mechanism  204  more convenient. Additionally, a shape and size of the portion of release mechanism  204  that protrudes from the adhesive bond can be varied to prevent surrounding circuitry or components from blocking access to release mechanism  204 . For example, in some embodiments the protruding portion of release mechanism  204  can be an elongated narrow tab, a hook, a loop, or any shape that allows a technician or machine to gain purchase on the tab. While batteries  202  are depicted in substantially rectangular configurations it should be understood that the batteries can also have other geometries.  FIG. 2  also shows a close up view showing a perspective view of a particular battery  202  and release mechanism  204 . Battery  202  is adhered to base  102  with an adhesive bond. Release mechanism  204  is embedded in the adhesive bond.  FIG. 2  also depicts a number of pillars  206  embedded within the adhesive layer, which will be discussed in detail in the description of  FIG. 3A . Pillars  206  are shown relative to the size of battery  202 . While this embodiment shows only 9 pillars in a regular pattern it should be understood that a shape, size, and/or layout of pillars  206  can be varied to achieve any number of design objectives. 
       FIG. 3A  depicts a cross sectional side view of adhesive bond  300  in accordance with section line A-A of  FIG. 2 . Adhesive bond  300  can be utilized to secure a first component to a second component. For exemplary purposes,  FIG. 3A  shows adhesive bond  300  securing battery  202  and base  102 ; however, it should be understood that adhesive bond  300  can join any two components and use of this specific example should not be construed as limiting. Adhesive bond  300  includes adhesive layers  302  and  304  that are adhesively coupled to battery  202  and housing  102  respectively. In this way, adhesive bond  300  is adhesively coupled to both components. Pillars  206  join adhesive layers  302  and  304  to each other and can be formed from a compressible material that is easily susceptible to shearing forces. In some embodiments, pillars  206  can be formed from foam and have a cylindrical geometry. In some embodiments, pillars  206  can each have different geometries. Pillars  206  can establish a gap between adhesive layers  302  and  304 . While pillars  206  can be subject to a certain amount of compression during an assembly process, the material of pillars  206  can maintain the gap at a minimum size that accommodates various other elements within adhesive bond  300 . In particular, liners  310  and  312  can be formed from non-adhesive material that is adhesively coupled with interior facing surfaces of adhesive layers  302  and  304 . In this way, liners  310  and  312  mask or cover bonding surfaces of adhesive layers  302  and  304 . Liners  310  and  312  can define openings  308  to accommodate pillars  206  so that only portions of the bonding surfaces that are coupled with pillars  206  remain exposed. 
     Release mechanism  204  is positioned between liners  310  and  312 . In this way, liners  310  and  312  can prevent release mechanism  204  from contacting adhesive layers  302  and  304 , as such contact can result in undesirable adhesive coupling between release mechanism  204  and adhesive layers  302  or  304 . A portion of release mechanism  204  can protrude from first and second adhesive layers  302  and  304 . A user or a machine can grip and pull upon the protruding portion of release mechanism  204  to impart a shear force on pillars  206 . Although pillars  206  and liner  310  and  312  are depicted as separate components, in some embodiments, pillars  206  may be molded into liner  310  and/or liner  312 . 
       FIG. 3B  depicts a cross sectional top view of release mechanism  204  and pillars  206  in accordance with section line B-B.  FIG. 3B  additionally depicts a number of pillars  206  protruding through openings  308  in release mechanism  204 . Release mechanism  204  is formed from a single piece of material. In some embodiments, release mechanism  204  can be formed by performing a die-cutting operation on a single sheet of polymeric film. As depicted, pillars  206  pass through openings  308  of release mechanism  204 . In some embodiments, a shape of openings  308  can correspond directly to a geometry of pillars  206 . In other embodiments a shape of openings  308  can be substantially larger than a corresponding pillar it surrounds. To increase a strength of the adhesive bond a size of pillars  206  can be increased, thereby increasing an area across which adhesive can join adhesive layers  302  and  304 . An area taken up by the pillars can be increased as long as pillars  206  are not too thick to be sheared through by release mechanism  204 . The relative cross sectional area of pillars  206  and the cross sectional area of release mechanism  204  can vary based on various factors. For example, the cross sectional area of pillars  206  would need to be sized to ensure structure integrity of the adhesive bond during circumstances such as drop events. Additionally, the cross sectional area of release mechanism  204  would need to be a certain size to ensure structural integrity when shearing pillars  206 . 
     While  FIG. 3B  depict pillars  206  being formed in a cylindrical shape, it should be understood that pillars  206  can be formed in any number of shapes, so long as pillars  206  join first adhesive layer  302  and second adhesive layer  304 . In some cases, pillars  206  are shaped in order to decrease the force required for release mechanism  204  to shear through pillars  206 . For example, pillars  206  may be formed in a teardrop, rounded, or square shape. Additionally, pillars  206  can be formed from either open cell or closed cell foam. Liner  310  can be formed of PET or any material that minimizes friction between liner  310  and release mechanism  204 . Release mechanism  204  can be formed from any thin film material including PET, and other plastic or metallic materials. When release mechanism  204  is formed of a metallic materials that is ferromagnetic, force may be introduced to release mechanism  204  via a magnetic field. 
     In an alternative embodiment, release mechanism  204  may also be formed from nitinol. Nitinol, or Nickel titanium is a metal alloy that can be resistively or inductively heated when exposed to an electric current. Pillars  206  may be formed from foam or another material that structurally fails or weakens when exposed to elevated temperatures. A technician may attach electrodes to release mechanism  204  or bring an induction coil in close proximity to the release mechanism. Release mechanism is heated by the electric current to an elevated temperature. The heated release mechanism can cause the structural integrity of pillars  206  to weaken or otherwise fail, allowing the connection established by pillars  206  to be at least partially severed. 
       FIGS. 3C-3E  show cross sectional views of adhesive bond  300  in accordance with section line A-A in which a force is imparted on release mechanism  204  that causes release mechanism  204  to shear through pillars  206 .  FIG. 3C  shows adhesive bond  300  with no outside force imparted upon release mechanism  204 . Once a user applies a lateral force in direction  314  on release mechanism  204 , release mechanism  204  engages pillars  206  and begins to shear through the pillars as depicted in  FIG. 3D . In some cases, such as in an automated rework line a machine can be configured to pull on the release mechanism  204 . When release mechanism  204  completely shears through pillars  206 , the bond between the first adhesive layer  302  and the second adhesive layer  304  breaks as depicted in  FIG. 3E . In this way, adhesive bond  300  is broken. 
       FIG. 4A  shows adhesive bond  400 . Adhesive bond  400  can utilize adhesive layers which include a number of alternating bonding and non-bonding layers. As depicted, first adhesive layer  302  includes first bonding layer  402 , non-bonding layer  404 , and second bonding layer  406 . Additionally, second adhesive layer includes first bonding layer  402 , non-bonding layer  404 , and second bonding layer  406 . Utilizing alternating bonding and non-bonding layers instead of one monolithic adhesive layer allows for utilizing different types of adhesives. For example, bonding layer  406  may be formed from a first adhesive that more efficiently bonds with battery  202 , and bonding layers  402  may be formed from a second adhesive that more efficiently binds with pillars  206 . It should be understood that adhesive layers  302  and  304  could include any number of alternating bonding and non-bonding layers. 
       FIG. 4B  shows adhesive bond  450 . Adhesive bond  450  can utilize consolidated pillar structure  452  which is formed by molding pillars  206  and liners  310  and  312  into one structure. Combining the pillars and liners into one structure would increase the adhesive power of adhesive bond  450 . Consolidated pillar structure  452  maintains an adhesive bond between the first and second adhesive layers. Consolidated pillar structure  452  also prevent release mechanism  204  from contacting the first and second adhesive layers thereby allowing release mechanism to float in adhesive bond  450 . In some embodiments, such as the embodiment depicted in  FIG. 4B , consolidated pillar structure  452  is formed of a monolithic material. This material may be either open cell or closed cell foam. In other embodiments consolidated pillar structure  452  may be a heterogeneous material wherein the portion of the consolidated pillars analogous to pillars  206  is a first material and the portion of the consolidated pillars analogous to liners  310  and  312  is a second material. For example, the first material may be foam and the second material may be PET. While consolidated pillar structure  452  is depicted as being formed from pillars  206  and liners  310  and  312 , other forms are possible. In some embodiments, consolidated pillars  452  may be formed by molding pillars  206  into liners  310  and  312 . In other embodiments, pillars  206  may be molded into one of liner  310  and liner  312 . For example, pillars  206  may be molded into liner  310 , thereby forming a partially consolidated pillar structure. 
       FIG. 5A  shows adhesive bond  500 . Adhesive bond  500  can utilize release mechanism  502 , which is embedded between liners  310  and adhesive layers  302  and  304 . Pillars  206  maintain an interior volume between adhesive layers  302  and  304  so that release mechanism  502  can float inside adhesive bond  500 . Release mechanism  502  can be formed of a thin polymeric sheet with openings  308  formed during a stamping or die-cutting operation. In some embodiments, such as the embodiments depicted, a particular type of die-cutting operation can be applied that is sometimes referred to as coining. A coining operation can produce a clean and sharpened edge by thinning a portion of the release layer that surrounds and defines openings  308 . In this way, sharp edges  504  can be produced that help to concentrate the force applied through the release layer, which reduces an amount of force required to shear through pillars  206 . While sharp edges  504  are depicted many other geometries are also possible. Possible alternative edge geometries include rounded edges, or any edge geometry that reduces the force required to shear through pillars  206 . 
       FIG. 5B  depicts a perspective view of a specific implementation of adhesive bond  400  in which release mechanism  204  has been formed by a coining operation. Adhesive bond  400  is shown securing battery  202  to base  102 . Release mechanism  204  is positioned between a first adhesive layer  302  and second adhesive layer  304 . First and second adhesive layers  302  and  304  each include a first bonding layer  402 , a non-bonding layer  404 , and a second bonding layer  406 . Pillars  206  are adhesively coupled with first bonding layers  402 . Liner  310  can prevent the release mechanism from contacting first bonding layers  402  as contact between release mechanism  204  and first bonding layers  402  can result in undesirable adhesive coupling between release mechanism  204  and first bonding layers  402 . Utilizing alternating bonding and non-bonding layers instead of one monolithic adhesive layer allows for utilizing different types of adhesives. For example, bonding layer  406  may be formed from a first adhesive that more efficiently binds with battery  202 , and bonding layers  402  may be formed from a second adhesive that more efficiently binds with pillars  206 . An edge of release mechanism  204  facing  204  facing pillars  206  is formed by a coining operation in order to reduce the amount of force required to shear through pillars  206 . 
       FIG. 6A  shows a top cross-sectional view of release mechanism  602  that defines a number of offset openings. Release mechanism  602  can be embedded between a liner, a first adhesive layer and a second adhesive layer to form adhesive bond  600 . Pillars  606 ,  610 , and  614  maintain an interior volume between the adhesive layers, allowing release mechanism  602  to float between the adhesive layers and liners. As depicted, pillars  606 ,  610 , and  614  extend through openings  604 ,  608 , and  612 . Offset openings  604 ,  608 , and  612  are depicted as being offset variable distances from pillars  606 ,  610 , and  614 . A technician or machine may apply a lateral force in direction  616 . Because of the variable offset between the pillars and the openings, release mechanism can initially engage a single pillar or a group of pillars that number less than the total amount of pillars. In this way, less force is required to shear through the pillars than if the release mechanism were to engage all the pillars concurrently. While openings  604 ,  608  and  612  as well as pillars  606 ,  610 , and  614  are depicted as singular sets of openings and pillars, one opening may simultaneously engage a number of pillars. For example, pillar  606  can represent a group of pillars extending through opening  604 . While openings  604 ,  608 , and  612  are depicted as rounded slots, the openings may also have any number of geometries, including circular, oval, or square geometries. 
       FIGS. 6B-6C  depict release mechanism shearing through pillars  606  and  610  as a technician or machine applies a lateral force in direction  616  to release mechanism  602 . First, only opening  604  engages pillar  606  as shown in  FIG. 6B . As a result, less force is required to shear through pillar  606  than if all openings  604 ,  608 , and  612  were engaged with pillars. After pillar  606  is completely sheared through, opening  608  engages pillar  610  as depicted in  FIG. 6C . After pillar  610  is sheared through, opening  612  engages pillar  614  and shears through pillar  614 . Because release mechanism  602  only engages a single pillar at a given time, less force is required to shear through the pillars, albeit over a longer pull distance. 
       FIGS. 6D-6E  depicts how release mechanism  602  can be equally effective being pulled in direction  618 . Release mechanism  602  is depicted shearing through pillars  614  and  610 . At first, as depicted in  FIG. 6D , only opening  612  engages pillar  614 . Release mechanism  602  shears through pillar  614  with one of the edges the defines opening  612  while pillar  606  remains unengaged with release mechanism  602 . While release mechanism  602  shears through pillar  614 , release mechanism  602  begins to engage pillar  610  through opening  608 .  FIG. 6E  depicts release mechanism  602  fully sheared through pillar  614  and release mechanism engaging pillar  610 . As release mechanism  602  shears through pillar  610 , release mechanism  602  begins to engage pillar  606  through opening  604 . In this way, release mechanism  602  only engages a single pillar  606 ,  610 , or  614  at a given point in time thereby reducing the amount of force required at a given point in time to completely sever adhesive bond  600 . 
       FIG. 7  illustrates a flow chart depicting a method  700  for manufacturing and utilizing an adhesive bond in accordance with an embodiment of the invention. As shown, method  700  begins at step  702  which involves preparing the surface of the first and second components. For example the first component can be an enclosure of a portable computer device and the second component can be a battery. Preparation can involve cleaning the surface of the first and second components. Step  704  involves applying a first adhesive layer to the second component. Step  706  involves applying a number of pillars to the first adhesive layer. In step  708  a first liner is applied to the first adhesive layer. In step  710  the release mechanism is positioned upon the first liner. In step  712  a second liner is applied above the release mechanism. Finally, step  714  involves applying a second adhesive layer to the second liner and the second component. 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. 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 specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described 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: 20140929
Publication Date: 20160405
Grant Date: 20160405
Priority Date: 20140929
Inventors: ROCKFORD DAVID M.
LEGGETT WILLIAM F.
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T428/14", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1658", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1616", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/24802", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2205/302", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2201/128", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/28", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/0232", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/1476", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/0246", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2201/606", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2201/20", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/0264", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/0225", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y02E60/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2301/502", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2203/33", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/28", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24802", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2301/124", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24802", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2301/204", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "C09J7/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/28", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2301/204", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/38", "inventive": true, "first": false, "tree": "[]"}, {"code": "C09J2301/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1616", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1616", "inventive": true, "first": false, "tree": "[]"}, {"code": "C09J2301/502", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/14", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1658", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1658", "inventive": true, "first": true, "tree": "[]"}, {"code": "C09J2203/33", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1635", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/1476", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2301/302", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2301/124", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/38", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/14", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1635", "inventive": true, "first": false, "tree": "[]"}, {"code": "C09J2301/21", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2301/21", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2301/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/1476", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 55584314