PATENT DOCUMENT

Publication Number: US-9280183-B2
Application Number: US-201113239190-A
Country: US
Kind Code: B2

Title: Advanced techniques for bonding metal to plastic

Abstract:
Techniques for combining a polymer layer and a metal layer to form a multi-layer structure are disclosed. In one embodiment, an intermediate layer having pores, openings or voids is secured to the metal layer, and then the polymer layer is molded to the intermediate layer, whereby the pores, openings or voids in the surface of the intermediate layer serve to facilitate securing of the polymer layer to the metal layer. The multi-layer structure is suitable for use in as a portion of a housing for an electronic device, such as a portable electronic device.

Claims:
What is claimed is: 
     
       1. A method for forming a housing for a portable electronic device, the method comprising:
 providing a metal housing layer for the housing for the portable electronic device; 
 plating substantially all of a top layer of the metal housing layer with a porous metal layer; 
 molding a polymer housing layer onto the porous metal layer; and 
 subsequently attaching one or more internal structural components internal to the housing. 
 
     
     
       2. A method as recited in  claim 1 , wherein the metal housing layer is an inner layer for the housing, and the polymer housing layer is an outer layer. 
     
     
       3. A method as recited in  claim 1 , wherein the polymer housing layer is an inner layer, and the metal housing layer is an outer layer for the housing. 
     
     
       4. A method as recited in  claim 1 , wherein the porous metal layer includes a plurality of pores. 
     
     
       5. A method as recited in  claim 1 , wherein the porous metal layer includes a plurality of voids or openings. 
     
     
       6. A method as recited in  claim 1 ,
 wherein the metal layer comprises aluminum or stainless steel, and 
 wherein the porous metal layer primarily includes Nickel. 
 
     
     
       7. A method as recited in  claim 1 , wherein the thickness of the porous metal layer is 0.5-3 microns. 
     
     
       8. A method as recited in  claim 1 , wherein the polymer housing layer comprises a polymer, and wherein the polymer is Polyphenylene Sulfide. 
     
     
       9. A method as recited in  claim 1 , wherein the housing has a thickness of less than 3 mm. 
     
     
       10. A method as recited in  claim 1 , wherein the porous metal layer comprises Nickel, Zinc and/or Copper. 
     
     
       11. A method as recited in  claim 1 , wherein the plating further comprises:
 plating the metal housing layer with a first porous metal layer; and 
 plating a second porous metal layer on a top surface of the first porous metal layer. 
 
     
     
       12. A method as recited in  claim 11 , wherein the first porous metal layer is nickel and the second porous metal layer is zinc. 
     
     
       13. A method as recited in  claim 1 , wherein the molding further comprises applying a primer to the porous metal layer prior to molding the polymer housing layer onto the porous metal layer. 
     
     
       14. A method as recited in  claim 13 , wherein the primer is a hot melting primer film. 
     
     
       15. A method as recited in  claim 12 , wherein the portable electronic device is a computing device. 
     
     
       16. A method for forming a housing for a portable electronic device, the method comprising:
 providing a metal housing layer for the housing for the portable electronic device; 
 plating substantially all of a top layer of the metal housing layer with a porous metal layer; 
 molding a polymer housing layer onto the porous metal layer; and 
 subsequently attaching one or more internal structural components internal to the housing on the metal housing layer, 
 wherein the polymer housing layer is an outer layer for the housing. 
 
     
     
       17. A method as recited in  claim 16 , wherein the thickness of the intermediate layer is 0.5-3 microns. 
     
     
       18. A method as recited in  claim 16 , wherein the housing has a thickness of less than 3 mm. 
     
     
       19. A method as recited in  claim 16 , wherein the plating further comprises:
 plating the metal housing layer with a first porous metal layer; and 
 plating a second porous metal layer on a top surface of the first porous metal layer. 
 
     
     
       20. A method as recited in  claim 19 , wherein the first porous metal layer is nickel and the second porous metal layer is zinc. 
     
     
       21. A method as recited in  claim 19 , wherein the portable electronic device is a mobile communication device. 
     
     
       22. A method as recited in  claim 16 , wherein the molding further comprises applying a primer to the porous metal layer prior to molding the polymer housing layer onto the porous metal layer. 
     
     
       23. A method as recited in  claim 16 , wherein the porous metal layer comprises Nickel, Zinc and/or Copper. 
     
     
       24. A method as recited in  claim 16 , wherein the polymer housing layer comprises a polymer, and wherein the polymer is Polyphenylene Sulfide. 
     
     
       25. A method for forming a housing for a portable electronic device, the method comprising:
 providing a metal housing layer for the housing for the portable electronic device; 
 plating the metal housing layer with a porous metal layer, the porous metal layer having a plurality of pores, the diameter of the pores is less then five microns; 
 injection molding a polymer housing layer onto the porous metal layer such that polymer material at least partially fills the pores of the porous metal layer; and 
 subsequently attaching one or more internal structural components internal to the housing.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority benefit of: (I) U.S. Provisional Application No. 61/470,662, filed Apr. 1, 2011, and entitled “ADVANCED TECHNIQUES FOR BONDING METAL TO PLASTIC,” which is hereby incorporated herein by reference; and (ii) U.S. Provisional Application No. 61/476,688, filed Apr. 18, 2011, and entitled “ADVANCED TECHNIQUES FOR BONDING METAL TO PLASTIC,” which is hereby incorporated herein by reference. 
    
    
     BACKGROUND 
     Conventionally, a portable electronic device has a housing that encases various structures as well as electrical components of the portable electronic device. These housing tend to be either plastic or metal. While housing have been able to use in combination of plastic and metal, their combination together is problematic in robust, low profile designs. Hence, there remains a need for improved techniques to use a combination of metal and plastic in housing designs for portable electronic devices. 
     SUMMARY 
     The invention pertains to techniques for combining a polymer layer and a metal layer to form a multi-layer structure. In one embodiment, an intermediate layer having pores, openings or voids is secured to the metal layer, and then the polymer layer is molded to the intermediate layer, whereby the pores, openings or voids in the surface of the intermediate layer serve to facilitate securing of the polymer layer to the metal layer. The multi-layer structure is suitable for use in as a portion of a housing for an electronic device, such as a portable electronic device. 
     The invention can be implemented in numerous ways, including as a method, system, device, or apparatus. Several embodiments of the invention are discussed below. 
     As a method for forming a multi-layer structure for an electronic device, one embodiment can, for example, include at least the operations of: obtaining a metal layer; placing an intermediate layer on the metal layer, the intermediate layer including openings or voids at least at an exposed surface; and forming a polymer-based layer on the exposed surface of the intermediate layer. 
     As a method for forming a housing for a portable electronic device, one embodiment can, for example, include at least: providing a metal housing layer for the housing for the portable electronic device; plating the metal layer with a porous metal layer; molding a polymer housing layer onto the porous metal layer; and subsequently attaching one or more internal structural components internal to the housing. 
     As a consumer electronic device, one embodiment can, for example, include at least at least one housing assembly. The at least one housing assembly can include at least: a first housing layer, a second housing layer, and an intermediate porous layer. The intermediate porous layer is interposed between at least a portion of the first housing layer and the second housing layer. The intermediate porous layer can be formed on the first housing layer, and the second housing layer can be formed on the intermediate porous layer. 
     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 invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  is a multi-layer structure formation process according to one embodiment. 
         FIGS. 2A and 2B  illustrate assembly of a multi-layer structure according to one embodiment. 
         FIG. 3A  illustrates a cross-sectional view of a multi-layer structure according to another embodiment. 
         FIG. 3B  illustrates a cross-sectional view of a multi-layer structure according to still another embodiment. 
         FIG. 4  is a multi-layer structure formation process according to another embodiment. 
         FIGS. 5A and 5B  illustrate cross-sectional views of an electronic device housing according to one embodiment. 
         FIGS. 6A and 6B  are diagrammatic representations of electronic device according to one embodiment. 
         FIGS. 7A and 7B  are diagrammatic representations of electronic device according to another embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The invention pertains to techniques for combining a polymer layer and a metal layer to form a multi-layer structure. In one embodiment, an intermediate layer having pores, openings or voids is secured to the metal layer, and then the polymer layer is molded to the intermediate layer, whereby the pores, openings or voids in the surface of the intermediate layer serve to facilitate securing of the polymer layer to the metal layer. The multi-layer structure is suitable for use in as a portion of a housing for an electronic device, such as a portable electronic device. 
     The following detailed description is illustrative only, and is not intended to be in any way limiting. Other embodiments will readily suggest themselves to skilled persons having the benefit of this disclosure. Reference will now be made in detail to implementations as illustrated in the accompanying drawings. The same reference indicators will generally be used throughout the drawings and the following detailed description to refer to the same or like parts. It should be appreciated that the drawings are generally not drawn to scale, and at least some features of the drawings have been exaggerated for ease of illustration. 
     Embodiments are discussed below with reference to  FIGS. 1-7B . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. 
       FIG. 1  is a multi-layer structure formation process  100  according to one embodiment. The multi-layer structure formation process  100  is a process that can be used in to manufacture or assemble of structural components for a variety of different purposes. As one example, the multilayer structure being formed can be used for at least a portion of a housing for an electronic device, such as a portable electronic device. 
     The multi-layer structure formation process  100  can initially obtain  102  a metal layer. Next, an intermediate layer can be placed  104  on the metal layer. The intermediate layer is typically also a metal layer that can be placed  104  on the metal layer in a variety of different ways. For example, the intermediate layer can be placed  104  on the metal layer by a plating process, a deposition process, or some other process suitable for securing a thin metal layer to the metal layer (base metal layer). The intermediate layer can, in one embodiment, pertain to a thin metal layer, such as a thin layer of nickel, zinc or copper, that inherently or through processing includes pores, openings or voids. 
     After the intermediate layer has been placed  104  on the metal layer, a polymer-based layer can be formed  106  on the exposed surface of the intermediate layer. Here, the formation  106  of the polymer-based layer can be achieved through an injection molding process whereby a molten polymer is dispensed onto the intermediate layer and formed into the polymer-based layer. When the polymer-based layer is being formed  106 , the molten polymer is able to embed itself with in the various pores, openings or voids in the intermediate layer. 
     The resulting multi-layer structure is thus a structure formed from the metal layer, the intermediate layer and the polymer-based layer. Each of the layers can be relatively thin, such as on the order of 1 mm or less. Although securing a polymer-based layer to a metal layer directly is not easily achieved given the differing characteristics of the materials, through use of the intermediate layer, the resulting multi-layer structure is able to be securely bonded together. More particularly, the intermediate layer, being a metal, can be bonded to the base metal layer through a plating process or deposition process, both of which can form thin layers which are strongly secured to the base metal layer. Additionally, since the intermediate layer includes pores, openings or voids, the molding of the polymer-based layer onto the exposed surface of the intermediate layer enables the polymer to at least partially fill into the pores, openings or voids prior to being cured. Consequently, the pores, openings or voids enable the polymer-based layer to be strongly secured to the intermediate layer and thus to the base metal layer. The resulting multilayer structure is thus a strongly bonded, thin structure that is suitable for a variety of purposes, including the formation of at least a portion of a housing for an electronic device. 
       FIGS. 2A and 2B  illustrate assembly of a multi-layer structure  200  according to one embodiment. The multi-layer structure  200  is shown disassembled in  FIG. 2A , and is shown assembled in  FIG. 2B . The multi-layer structure  200  is a structure that results from a metal layer  202 , an intermediate layer  204  and a polymer-based layer  206 . As shown in  FIG. 2A , each of the layers is rather thin because the multi-layer structure  200  is typically thin. For example, in one embodiment, each of the layers have a thickness of less than 1 mm, and the thickness of the multi-layer structure  200  is less than 3 mm. The thickness of each of the layers can also differ. The metal layer  202  can be formed of aluminum, stainless steel, or any other metal that can be plated. The intermediate layer  204  can, for example, be formed of nickel, zinc, or copper. The intermediate layer  204  is porous and the pores are small, for example such as a diameter of approximately one to several microns. The thickness of the intermediate layer  204  can vary depending on the plated material. For example, the thickness of the intermediate layer  204  can be on the order of about 0.5 to 3 microns. The intermediate layer  204  may itself be formed in multiple layers, such as when an initial strike plating is used. One example of multiple layers for the intermediate layer  204  would be an initial nickel strike plating followed by a zinc plating. The polymer-based layer  206  can be formed of a polymer material, such as Polyphenylene Sulfide (PPS), glass-reinforced PPS, polycarbonate or other engineered plastics, which bond well with the intermediate layer  204 . Other polymers may be used though some may bond better if a primer is first applied to the intermediate layer  204 , such as a hot melting primer film. 
     Additionally, although not illustrated in  FIGS. 2A and 2B , some or all of the multi-layer structure  200  can also be subjected to one or more finishing operations. Examples of finishing operations include polishing, anodizing, painting, marking, and the like. The metal layer  202 , when formed of aluminum, can, for example, be anodized. 
       FIG. 3A  illustrates a cross-sectional view of a multi-layer structure  300  according to another embodiment. The multi-layer structure  300  includes a metal layer  302 , an intermediate layer  304  and a polymer-based layer  206 . Similar to that shown in  FIG. 2B , the intermediate layer  304  is bonded to the metal layer  302 , and then the polymer-based layer  306  is bonded to the intermediate layer  304 . More particularly, as illustrated in  FIG. 3A , at least a surface opposing the polymer-based layer  306  includes a plurality of pores, openings or voids  308 . In  FIG. 3A , the pores, openings or voids  308  are arbitrarily configured such that their placement, size or depth tends to be arbitrary. 
       FIG. 3B  illustrates a cross-sectional view of a multi-layer structure  350  according to still another embodiment. The multi-layer structure  350  includes a metal layer  352 , an intermediate layer  354  and a polymer-based layer  256 . Similar to that shown in  FIG. 2B , the intermediate layer  354  is bonded to the metal layer  352 , and then the polymer-based layer  356  is bonded to the intermediate layer  354 . More particularly, as illustrated in  FIG. 3B , at least a surface opposing the polymer-based layer  356  includes a plurality of pores, openings or voids  358 . In  FIG. 3B , the pores, openings or voids  358  are configured by controlled processing that their placement, size or depth tends to be uniform. For example, an etch process using an acid (e.g., nitric acid) can be used to uniformly form the pores, openings or voids  358 . 
       FIG. 4  is a multi-layer structure formation process  400  according to another embodiment. The multi-layer structure formation process  400  is a process that can be used in to manufacture or assemble a portion of a housing for an electronic device, such as a portable electronic device. 
     The multi-layer structure formation process  400  can initially provide  402  a metal housing layer for a housing of an electronic device. Next, the metal housing layer can be plated  404  with a porous metal layer. Here, the metal housing layer is formed of metal and can be plated, through electroplating, to form the porous metal layer. Although electroplating does not typically produce a porous metal layer, the electroplating of Nickel onto aluminum can be performed such that the plating yields the porous metal layer. Here, the plating can be referred to as porous electro-plating which yields the desired porous metal layer. Alternatively, additional processing can serve to form openings or voids in the metal layer that is plated onto the metal housing layer. For example, the additional processing can include an etching process using, for example, an acid (e.g., nitric acid for Ni removal). 
     Next, a polymer housing layer can be molded  406  onto the porous metal layer. Here, the polymer housing layer can be molded  406  through injection molding of a polymer into a mold to form the polymer housing layer on the porous metal layer. Through the injection molding, the polymer being injected prior to being cured also at least partially fills the pores, openings or voids in the porous metal layer. After the porous metal layer has been cured, the housing formed by the multi-layer structure can be used as a portion of a housing for an electronic device. In such case, one or more structural components can thereafter be attached  408  to the housing. Further processing can also be performed to couple other structural components to the multilayer housing so as to form the electronic device. 
     Given that the multi-layer structure can be used for electronic devices, and often compact electronic devices, the structural components tend to be rather small. For example, a structural component is typically thin, particularly when used with portable electronic devices, such as on the order of thickness of less than 5 mm, or in some cases less than 1 mm. 
       FIGS. 5A and 5B  illustrate cross-sectional views of an electronic device housing  500  according to one embodiment. The electronic device housing  500  includes an outer housing member  501  supported and protected by a protective side member  502 . The protective side member  502  being positioned adjacent sides of the outer housing member  501 . The protective side members  502  can provide a thin layer of material positioned tightly adjacent sides of the outer housing member  501 , thereby buffering impact at the sides of the outer housing member  501 . The protective side member  502  can also support the outer housing member  501  and can serve to secure the outer housing member  501  to other portions of the electronic device housing  500 . In one embodiment, the protective side member  502  extends around all sides of the outer housing member  501 . In another embodiment, the protective side member  502  extends around those of the sides of the outer housing member  501  that would otherwise be exposed. 
     As shown in  FIG. 5A , the outer housing member  501  can be secured to a multi-layer support structure  504  of the electronic device housing  500 . The multi-layer support structure  504  can, for example, be an outer housing member for the electronic device housing  500 . 
     The protective side member  502  can be secured tightly adjacent the sides of the outer housing member  501  using an adhesive  506 . In one embodiment, the adhesive  506  can be applied as a layer of adhesive that is provided around a periphery of an inner side of the outer housing member  501 . The adhesive  506  can thus serve to secure the protective side member  502  against the sides of the outer housing member  501 . Also, the adhesive  506  can, for example, be a temperature activated adhesive which, once activated, can form a strong bond between the outer housing member  501  and the peripheral protective side member  502  via the adhesive  508 . An internal space  508  is provided internal to the electronic device housing  500  whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. 
     The various members, parts or assemblies of the electronic device housing  500  can be formed of any of a variety of materials, e.g., glass, polymers or metal. In one embodiment, the outer housing member  501  is glass, and the protective side member  502  is be formed from polymer (e.g., thermoplastic). More particularly, in some embodiments, the protective side member  502  can be a structurally strengthened polymer (e.g., thermoplastic). As an example, the protective side member  502  can be a polymer, such as polyarylamide, nylon or polycarbonate, which can be structurally strengthened by including glass fibers. For example, some examples of some structurally strengthened polymers include 50% glass filled nylon and 30% glass filled polycarbonate. 
     The multi-layer support structure  504  is formed from a plurality of layers as discussed above. For example, the multi-layer support structure  504  Formed from metal or polymer (e.g., plastic). The multi-layer support structure  504  is formed from an outer layer  510 , an intermediate layer  512  and an inner layer  514 . In one embodiment, the outer layer  510  is a metal layer, the intermediate layer  512  is a metal layer formed (e.g., plated) on the outer layer  510 , and the inner layer  514  is a polymer layer. In an alternative embodiment, the inner layer  514  is a metal layer, the intermediate layer  512  is a metal layer formed e.g., plated) on the inner layer  514 , and the outer layer is a polymer layer. 
       FIG. 5B  is a cross-sectional assembly diagram for the electronic device housing  500  shown in  FIG. 5A , according to one embodiment. The outer housing member  501  has a top surface and a bottom surface. The bottom surface of the outer housing member  501  has adhesive  506  applied as a layer of adhesive that is provided around a periphery of the bottom surface of the outer housing member  501 . The protective side member  502  can then be placed or formed adjacent the sides of the outer housing member  501 . Moreover, the protective side member  502  can also be adjacent and secured to an upper side portion  516  of the support structure  504 . When the protective side member  502  are provided at the sides (i.e., edges) of the outer housing member  501 , the protective side member  502  provides a buffer layer (e.g., bumper) that dampens impact induced at the sides of the outer housing member  501  of the electronic device housing  500 . 
     As previously discussed, the components being assembled can represent portions of a housing for electronic devices, such as portable electronic devices. Those portable electronic devices that are small and highly portable can be referred to as handheld electronic devices. A handheld electronic device may, for example, function as a media player, phone, internet browser, email unit or some combination of two or more of such. A handheld electronic device generally includes a housing and a display area. 
       FIGS. 6A and 6B  are diagrammatic representations of electronic device  600  according to one embodiment.  FIG. 6A  illustrates a top view for the electronic device  600 , and  FIG. 6B  illustrates a cross-sectional side view for electronic device  600  with respect to reference line A-A′. Electronic device  600  can include multi-layer housing  602  that has cover window  604  (e.g., glass or plastic cover) as a top surface. The multi-layer housing  602  can be formed from a plurality of layers of material (e.g., see  FIGS. 2A ,  2 B,  3 A and  3 B). Cover window  604  is primarily transparent so that display assembly  606  is visible through cover window  604 . Display assembly  606  can, for example, be positioned adjacent cover window  604 . Multi-layer housing  602  can also contain internal electrical components besides the display assembly, such as a controller (processor), memory, communications circuitry, etc. Display assembly  606  can, for example, include a LCD module. By way of example, display assembly  606  may include a Liquid Crystal Display (LCD) that includes a Liquid Crystal Module (LCM). In one embodiment, cover window  604  can be integrally formed with the LCM. Multi-layer housing  602  can also include an opening  608  for containing the internal electrical components to provide electronic device  600  with electronic capabilities. In one embodiment, multi-layer housing  602  may need not include a bezel for cover window  604 . Instead, cover window  604  can extend across the top surface of multi-layer housing  602  such that the edges of cover window  604  can be aligned (or substantially aligned) with the sides of multi-layer housing  602 . The edges of cover window  604  can remain exposed. Although the edges of cover window  604  can be exposed as shown in  FIGS. 6A and 6B , in alternative embodiment, the edges can be further protected. As one example, the edges of cover window  604  can be recessed (horizontally or vertically) from the outer sides of multi-layer housing  602 . As another example, the edges of cover window  604  can be protected by additional material placed around or adjacent the edges of cover window  604 . 
     Cover window  604  may generally be arranged or embodied in a variety of ways. By way of example, cover window  604  may be configured as a protective translucent piece that is positioned over an underlying display (e.g., display assembly  606 ) such as a flat panel display (e.g., LCD) or touch screen display (e.g., LCD and a touch layer). Alternatively, cover window  604  may effectively be integrated with a display, i.e., a translucent window may be formed as at least a portion of a display. Additionally, cover window  604  may be substantially integrated with a touch sensing device such as a touch layer associated with a touch screen. In some cases, cover window  604  can serve as the outer most layer of the display. 
       FIGS. 7A and 7B  are diagrammatic representations of electronic device  700  according to another embodiment.  FIG. 7A  illustrates a top view for electronic device  700 , and  FIG. 7B  illustrates a cross-sectional side view for electronic device  700  with respect to reference line B-B′. Electronic device  700  can include multi-layer housing  702  that has cover window  704  (e.g., glass or plastic cover) as a top surface. The multi-layer housing  702  can be formed from a plurality of layers of material (e.g., see  FIGS. 2A ,  2 B,  3 A and  3 B). In this embodiment, cover window  704  can be protected by side surfaces  703  of multi-layer housing  702 . Here, cover window  704  does not fully extend across the top surface of multi-layer housing  702 ; however, the top surface of side surfaces  703  can be adjacent to and aligned vertically with the outer surface of cover window  704 . Since the edges of cover window  704  can be rounded for enhanced strength, there may be gaps  705  that are present between side surfaces  703  and the peripheral edges of cover window  704 . Gaps  705  are typically very small given that the thickness of cover window  704  is thin (e.g., less than 3 mm). However, if desired, gaps  705  can be filled by a material. The material can be plastic, rubber, metal, etc. The material can conform in gap  705  to render the entire front surface of electronic device  700  flush, even across gaps  705  proximate the peripheral edges of cover window  704 . The material filling gaps  705  can be compliant. The material placed in gaps  705  can implement a gasket. By filling the gaps  705 , otherwise probably undesired gaps in the multi-layer housing  702  can be filled or sealed to prevent contamination (e.g., dirt, water) forming in the gaps  705 . Although side surfaces  703  can be integral with multi-layer housing  702 , side surface  703  could alternatively be separate from multi-layer housing  702  and, for example, operate as a bezel for cover window  704 . 
     Cover window  704  is primarily transparent so that display assembly  706  is visible through cover window  704 . Display assembly  706  can, for example, be positioned adjacent cover window  704 . Multi-layer housing  702  can also contain internal electrical components besides the display assembly, such as a controller (processor), memory, communications circuitry, etc. Display assembly  706  can, for example, include a LCD module. By way of example, display assembly  706  may include a Liquid Crystal Display (LCD) that includes a Liquid Crystal Module (LCM). In one embodiment, cover window  704  is integrally formed with the LCM. Multi-layer housing  702  can also include an opening  708  for containing the internal electrical components to provide electronic device  700  with electronic capabilities. 
     The front surface of electronic device  700  can also include user interface control  708  (e.g., click wheel control). In this embodiment, cover window  704  does not cover the entire front surface of electronic device  700 . Electronic device  700  essentially includes a partial display area that covers a portion of the front surface. 
     Cover window  704  may generally be arranged or embodied in a variety of ways. By way of example, cover window  704  may be configured as a protective translucent piece that is positioned over an underlying display (e.g., display assembly  706 ) such as a flat panel display (e.g., LCD) or touch screen display (e.g., LCD and a touch layer). Alternatively, cover window  704  may effectively be integrated with a display, i.e., a translucent window may be formed as at least a portion of a display. Additionally, cover window  704  may be substantially integrated with a touch sensing device such as a touch layer associated with a touch screen. In some cases, cover window  704  can serve as the outer most layer of the display. 
     The assembly techniques describe herein may be applied to assemble structural components used by any of a variety of electronic devices including but not limited handheld electronic devices, portable electronic devices and substantially stationary electronic devices. Examples of these include any known consumer electronic device that includes a display. By way of example, and not by way of limitation, the electronic device may correspond to media players, mobile phones (e.g., cellular phones), PDAs, remote controls, notebooks, tablet PCs, monitors, all in one computers and the like. 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     Additional details on side protective members as well as other characteristics or features for electronic device housings are contained in: (1) U.S. application Ser. No. 12/794,563, filed Jun. 4, 2010, and entitled “OFFSET CONTROL FOR ASSEMBLING AN ELECTRONIC DEVICE HOUSING,” which is hereby incorporated herein by reference; (2) U.S. application Ser. No. 12/944,671, filed Nov. 11, 2010, and entitled “INSERT MOLDING AROUND GLASS MEMBERS FOR PORTABLE ELECTRONIC DEVICES,” which is hereby incorporated herein by reference; ELECTRONIC DEVICE HOUSING,” which is hereby incorporated herein by reference; (3) U.S. application Ser. No. 13/072,586, filed Mar. 25, 2011, and entitled “BONDING STRUCTURAL COMPONENTS FOR PORTABLE ELECTRONIC DEVICES USING THERMALLY ACTIVATED ADHESIVE,” which is hereby incorporated herein by reference; (4) U.S. application Ser. No. 12/868,602, filed Aug. 25, 2010, and entitled “TECHNIQUES FOR MARKING A SUBSTRATE USING A PHYSICAL VAPOR DEPOSITION MATERIAL,” which is hereby incorporated herein by reference; and (5) U.S. application Ser. No. 11/964,652, filed Jul. 13, 2007, and entitled “METHODS AND SYSTEMS FOR FORMING A DUAL LAYER HOUSING,” which is hereby incorporated herein by reference. 
     In general, the steps associated with the methods of the present invention may vary widely. Steps may be added, removed, altered, combined, and reordered without departing from the spirit or the scope of the present invention. 
     The various aspects, features, embodiments or implementations of the invention described above may be used alone or in various combinations. 
     While this specification contains many specifics, these should not be construed as limitations on the scope of the disclosure or of what may be claimed, but rather as descriptions of features specific to particular embodiment of the disclosure. Certain features that are described in the context of separate embodiments may also be implemented in combination. Conversely, various features that are described in the context of a single embodiment may also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. 
     While embodiments and applications have been shown and described, it would be apparent to those skilled in the art having the benefit of this disclosure that many more modifications than mentioned above are possible without departing from the inventive concepts herein.

Metadata:
Filing Date: 20110921
Publication Date: 20160308
Grant Date: 20160308
Priority Date: 20110401
Inventors: TATEBE MASASHIGE
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T29/49982", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3481", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2081/04", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C45/14311", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2045/14868", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2705/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/14868", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2705/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3481", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2081/04", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14311", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49982", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 46927002