PATENT DOCUMENT

Publication Number: US-8934261-B2
Application Number: US-48942909-A
Country: US
Kind Code: B2

Title: Compact device housing and assembly techniques therefor

Abstract:
High density electronic device assemblies and techniques for forming high density electronic device assemblies are disclosed. These assemblies and techniques can be used to form compact electronic devices. In one embodiment, substrate arrangements that include a multiple-part substrate can be used to form a high density electronic device assembly. In another embodiment, one or more clips can be used in a high density electronic device assembly to provide mechanical and electrical interconnection between electrical structures that are to be removably coupled together as parts of the high density electronic device assembly. In still another embodiment, a removable cap (and a method for forming the removable cap) can be used for an electronic device housing.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a housing having at least one opening; 
 an electrical connector accessible from the opening in said housing, wherein the electrical connector has a plurality of sides; and 
 a printed circuit board assembly comprising a plurality of printed circuit boards having a plurality of electrical components coupled thereto, said printed circuit board assembly being provided within said housing and being electrically connected to said electrical connector, and said printed circuit board assembly being configured adjacent to a plurality of sides of said electrical connector, wherein said printed circuit board assembly has at least three sides that are each defined by a different one of the plurality of printed circuit boards and that are arranged to be adjacent to one of the sides of said electrical connector and a fourth side defined by one of the printed circuit boards, wherein the fourth side is attached to the electrical connector, and wherein the printed circuit board assembly comprises a bracket extending between a first portion and a second portion of one of the plurality of printed circuit boards, wherein the bracket extends adjacent to one of the plurality of sides of said electrical connector. 
 
     
     
       2. An electronic device as recited in  claim 1 , wherein said electrical connector is a peripheral port connector. 
     
     
       3. An electronic device as recited in  claim 1 , wherein said electronic device is a power adapter. 
     
     
       4. An electronic device as recited in  claim 1 , wherein the printed circuit board assembly comprises a first and a second end, and the electrical connector is located at the first end of the printed circuit board assembly. 
     
     
       5. An electronic device as recited in  claim 4 , further comprising a plug located at the second end of the printed circuit board assembly. 
     
     
       6. An electronic device, comprising:
 a housing having at least one opening; 
 an electrical connector accessible from the opening in said housing, wherein said electrical connector has a first side, a second side, a third side and a fourth side; and 
 a printed circuit board assembly comprising a plurality of printed circuit boards having a plurality of electrical components coupled thereto, said printed circuit board assembly being provided within said housing and being electrically connected to said electrical connector, and said printed circuit board assembly being configured adjacent to a plurality of sides of said electrical connector, 
 wherein said printed circuit board assembly has at least three sides that are each defined by a different one of the plurality of printed circuit boards and that are arranged to be adjacent to one of the sides of said electrical connector, wherein said printed circuit board assembly comprises: 
 a first printed circuit board provided adjacent the first side of said electrical connector; 
 a second printed circuit board provided adjacent the second side of said electrical connector; 
 a third printed circuit board provided adjacent the third side of said electrical connector; 
 a fourth printed circuit board provided adjacent the top side of said electrical connector, and wherein the fourth printed circuit board is smaller than the first printed circuit board. 
 
     
     
       7. An electronic device as recited in  claim 6 , wherein the printed circuit board assembly comprises a first and a second end, and the electrical connector is located at the first end of the printed circuit board assembly. 
     
     
       8. An electronic device as recited in  claim 7 , further comprising a plug located at the second end of the printed circuit board assembly. 
     
     
       9. An electronic device, comprising:
 a housing having at least one opening; 
 an electrical connector accessible from the opening in said housing; and 
 a printed circuit board assembly having a plurality of electrical components coupled thereto, said printed circuit board assembly being provided within said housing and being electrically connected to said electrical connector, and said printed circuit board assembly being configured adjacent to a plurality of sides of said electrical connector, 
 wherein said electrical connector has a top side, a bottom side, a left side and a right side, and 
 wherein said printed circuit board assembly comprises:
 a bottom printed circuit board attached to the electrical connector; 
 a bracket extending between a first portion and a second portion of the bottom printed circuit board, wherein the bracket extends adjacent to the bottom side of said electrical connector; 
 a first side printed circuit board provided adjacent the left side of said electrical connector; 
 a second side printed circuit board provided adjacent the right side of said electrical connector; and 
 a top printed circuit board provided adjacent the top side of said electrical connector. 
 
 
     
     
       10. An electronic device as recited in  claim 9 ,
 wherein said top printed circuit board is physically and electrically connected to said first side printed circuit board and said second side printed circuit board, and 
 wherein said bottom printed circuit board is physically and electrically connected to said first side printed circuit board and said second side printed circuit board. 
 
     
     
       11. An electronic device as recited in  claim 9 , wherein the first side printed circuit board and the second side printed circuit board are the same size. 
     
     
       12. An electronic device as recited in  claim 9 , wherein the printed circuit board assembly comprises a first and a second end, and the electrical connector is located at the first end of the printed circuit board assembly. 
     
     
       13. An electronic device as recited in  claim 10 , wherein said top printed circuit board is electrically connected to said bottom printed circuit board through at least one of said first side printed circuit board or said second side printed circuit board. 
     
     
       14. An electronic device as recited in  claim 11 , wherein the top printed circuit board is larger than the first and second side printed circuit boards. 
     
     
       15. An electronic device as recited in  claim 12 , further comprising a plug located at the second end of the printed circuit board assembly. 
     
     
       16. An electronic device as recited in  claim 14 , wherein the bottom printed circuit board is larger than the top printed circuit board.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 61/140,599, filed Dec. 23, 2008, entitled “COMPACT DEVICE HOUSING AND ASSEMBLY TECHNIQUES THEREFOR”, which is hereby incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to electronic device assemblies and, more particularly, to high density electronic device assemblies. 
     2. Description of the Related Art 
     Today, many electronic devices are highly portable so that they can be easily transported by their users. There are many examples of highly portable electronic devices, such as mobile phones, portable media players, personal digital assistants, portable power adapter, etc. There highly portable electronic devices are typically provided in small housings which makes both assembly and repair tedious and difficult. 
     Given the desire to make electronic devices smaller, there is a need to make electronic device housings even smaller. As the electronic device housings get smaller, the density of electrical components within the electronic device housings increases. With increasing density, the assembly and repair of the electronic devices becomes increasingly difficult. 
     Thus, there is a continuing need for improved structures and techniques that facilitate assembly of high density housings for electronic devices. 
     SUMMARY OF THE INVENTION 
     The invention pertains to compact electronic devices that have high density electronic device assemblies and/or to techniques for forming high density electronic device assemblies. 
     One aspect of the invention pertains to substrate arrangements for use in electronic device assemblies. The substrate arrangements can include multiple-part substrates that are able to be interconnected and utilized in confined spaces. A multiple-part substrate can pertain to a plurality of printed circuit boards that are electrically connected together when assembled into a printed circuit board arrangement. In one implementation, the printed circuit boards can be arranged around an electrical component (e.g., peripheral bus connector). The use of multiple printed circuit boards that are physically configured around other electrical components facilitates formation of compact electronic devices and/or their assembly. 
     Another aspect of the invention pertains to a clip for use in electronic device assemblies. The clip provides mechanical and electrical interconnection between two electrical structures, such as a contact pin and an electrical substrate (e.g., printed circuit board), that are coupled together as parts of an electronic device assembly. The clip also enables the mechanical and electrical interconnection to remain removable without substantial effort, which facilitates not only assembly but also repair of the electronic device. 
     Still another aspect of the invention pertains to a removable cap for an electronic device housing and a method for forming such a removable cap. In one implementation, the electronic device can pertain to a power adapter, and the removable cap can have one or more plugs integrally formed therewith. The one or more plugs can also have metal tips that can be attached. In one implementation, the metal tips are respectively removably attached to the one or more plugs. In one embodiment, the removable cap can be molded in longitudinal direction to have improved cosmetics, e.g., avoid parting lines or seams from forming in undesired portions. 
     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 printed circuit assembly, one embodiment of the invention can, for example, include at least: a bottom printed circuit board provided in a first plane; a first side printed circuit board attached to the bottom printed circuit board, the first side printed circuit board being provided in a second plane that is orthogonal to the first plane; a second side printed circuit board attached to the bottom printed circuit board, the first side printed circuit board being provided in the second plane offset from the first side printed circuit board; and a top printed circuit board attached to the first side printed circuit board and the second side printed circuit board, the top printed circuit board being provided in the first plane offset from the bottom printed circuit board. 
     An electronic device, one embodiment of the invention can, for example, include at least: a housing having at least one opening; an electrical connector accessible from the opening in the housing; and a printed circuit board assembly having a plurality of electrical components coupled thereto, the printed circuit board assembly being provided within the housing and being electrically connected to the electrical connector, and the printed circuit board assembly being configured adjacent to a plurality of sides of the electrical connector. 
     As a clip for assembly of an electronic device, one embodiment of the invention can, for example, includes at least: a base portion having an opening, the opening including a plurality of interference tabs; at least one upper flexure extending outward from the base portion; and at least one lower flexure extending outward from the base portion. The at least one upper flexure and the at least one lower flexure can be biased towards each other. 
     As a method for assembly an electronic device having at least one contact pin for electrical connection, one embodiment of the invention can, for example, include at least: providing a housing portion for the electronic device, the housing portion including at least one opening; inserting the at least one contact pin into the at least one opening of the housing portion; attaching a clip to the at least one contact pin to facilitate electrical connection with an electrical component of the electronic device; and attaching the housing portion to a housing of the electronic device. 
     As a portable power adapter for a portable electronic device, one embodiment of the invention can, for example, include at least: a housing having a removable cap; at least one metal contact pin; a printed circuit board provided within the housing; and a metal clip configured to couple to the at least one metal contact pin and to removably attach to the printed circuit board when the removable cap is attached to the housing. 
     Other aspects 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 elements, and in which: 
         FIG. 1  is a perspective view of a printed circuit assembly according to one embodiment of the invention. 
         FIG. 2  is a perspective assembly view for a printed circuit assembly according to one embodiment of the invention. 
         FIGS. 3A-3C  are illustrations of printed circuit boards that are suitable for attachment together to form a printed circuit assembly according to one embodiment of the invention. 
         FIGS. 4A and 4B  are perspective views of an assembled electronic device according to one embodiment of the invention. 
         FIGS. 5A-5C  are perspective views of an electronic device according to one embodiment of the invention. 
         FIGS. 6A-6D  are views of a clip according to one embodiment of the invention. 
         FIG. 6E  is a flow diagram of an assembly process for an electronic device according to one embodiment of the invention. 
         FIGS. 7A and 7B  are perspective views of a removable cap according to one embodiment of the invention. 
         FIGS. 8A and 8B  are partial perspective views illustrating attachment of a printed circuit board to a removable cap of a device housing according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention pertains to compact electronic devices that have high density electronic device assemblies and/or to techniques for forming high density electronic device assemblies. 
     Embodiments of the invention are discussed below with reference to  FIGS. 1-8B . 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. 
     One aspect of the invention pertains to substrate arrangements for use in electronic device assemblies. The substrate arrangements can include multiple-part substrates that are able to be interconnected and utilized in confined spaces. A multiple-part substrate can pertain to a plurality of printed circuit boards that are electrically connected together when assembled into a printed circuit board arrangement. In one implementation, the printed circuit boards can be arranged around an electrical component (e.g., peripheral bus connector). The use of multiple printed circuit boards that are physically configured around other electrical components facilitates formation of compact electronic devices and/or their assembly. 
       FIG. 1  is a perspective view of a printed circuit assembly  100  according to one embodiment of the invention. The printed circuit assembly  100  includes a bottom printed circuit board  102 , a top printed circuit board  104 , a first side printed circuit board  106 , and a second side printed circuit board  108 . As shown in  FIG. 1 , the printed circuit assembly  100  can arrange the printed circuit boards  102 - 108  in a rectangular or box-like configuration. For example, the first side printed circuit board  106  and the second side printed circuit board  108  can attach between the bottom printed circuit board  102  and the top printed circuit board  104 . In this example, the top printed circuit board  104  is substantially parallel to but offset from the bottom printed circuit board  104  by the first side printed circuit board  106  and the second side printed circuit board  108 . Also, in this example, the first side printed circuit board  106  and the second side printed circuit board  108  are positioned substantially orthogonal to the bottom printed circuit board  102 . The second side printed circuit board  108  is also substantially parallel to but offset from the first side printed circuit board  106 . 
     Although the printed circuit assembly  100  illustrated in  FIG. 1  uses an arrangement of four (4) separate printed circuit boards, it should be understood that in other embodiments, the number, size, shape (configuration) and/or arrangement of the printed circuit boards can vary, such as depending on its application. Generally, a plurality of separate printed boards are designed to reside in different planes (orientations) and to attach together during assembly such that adequate printed circuit board area is able to be efficiently provided in a confined space. Also, although the printed circuit assembly  100  arranges the printed circuit boards  102 - 108  in a rectangular manner, the arrangement can have other shapes or configurations, triangular, hexagonal, circular, curved or complex shapes. 
       FIG. 2  is a perspective assembly view for a printed circuit assembly according to one embodiment of the invention. The printed circuit assembly is assembled from a bottom printed circuit board  202 , a top printed circuit board  204 , a first side printed circuit board  206 , and a second side printed circuit board  208 . 
     The bottom printed circuit board  202  includes a first slot  210  for receiving a protrusion  212  of the first side printed circuit board  206 . By inserting the protrusion  212  into the first slot  210 , the first side printed circuit board  206  can be attached and supported by the bottom printed circuit board  202 . Further, the protrusion  212  can be secured within the opening  210  of the first side printed circuit board  206 . The bottom printed circuit board  202  also includes a second slot  214  for receiving a protrusion  216  of the second side printed circuit board  208 . By inserting the protrusion  216  into the second slot  214 , the second side printed circuit board  208  can be attached and supported by the bottom printed circuit board  202 . Further, the protrusion  216  can be secured within the opening  214  of the second side printed circuit board  208 . 
     The top printed circuit board  204  includes a first slot  218  for receiving a protrusion section  220  of the first side printed circuit board  206 . The first slot  218  of the top printed circuit board  204  can then be placed around the protrusion section  220  of the first side printed circuit board  206 . As a result, the top printed circuit board  204  can be supported by the first side printed circuit board  206 . In addition, the protrusion section  220  can be secured to the top side printed circuit board  204 . The top printed circuit board  204  also includes a second slot  222  for receiving a protrusion section  224  of the second side printed circuit board  208 . The second slot  222  of the top printed circuit board  204  can then be placed around the protrusion section  224  of the second side printed circuit board  208 . As a result, the top printed circuit board  204  can be supported by the second side printed circuit board  208 . In addition, the protrusion section  224  can be secured to the top side printed circuit board  204 . 
       FIGS. 3A-3C  are illustrations of printed circuit boards that are suitable for attachment together to form a printed circuit board arrangement according to one embodiment of the invention. 
       FIG. 3A  is a side view of a side printed circuit board  300  according to one embodiment of the invention. The side printed circuit board  300  includes a first protrusion  302  that facilitates connection of the side printed circuit board  300  with another printed circuit board, namely, a top or bottom printed circuit board. The side printed circuit board  300  also includes a second protrusion  306  that facilitates connection of the side printed circuit board  300  with another printed circuit board, namely, a top or bottom printed circuit board. Additionally, to facilitate electrical as well as mechanical interconnection between the side printed circuit board  300  and another printed circuit board, the first protrusion  302  can include one or more solder notches  304 . The solder notches  304  are notched inward so as to provide solder channels. In one implementation, although not shown in  FIG. 3A , the solder notches  304  can be rounded. Also, the second protrusion  306  can include one or more solder pads  308  that facilitate electrical as well as mechanical interconnection between the side printed circuit board and another printed circuit board. 
       FIG. 3B  is a perspective view of a top printed circuit board  320  according to one embodiment of the invention. The top printed circuit board  320  includes a top surface  322 . The top printed circuit board  320  includes a first opening  324  for receiving a first side printed circuit board, and a second opening  326  for receiving a second side printed circuit board. The first side printed circuit board and the second side printed circuit board can be configured as the side printed circuit board  300  illustrated in  FIG. 3A . Proximate to the first opening  324 , one more solder pads  328  can be provided on the top surface  322  of the top printed circuit board  320 . The one or more solder pads  328  facilitate electrical as well as mechanical interconnection between the first side printed circuit board inserted into the first opening  324 . For example, if the side printed circuit board  300  were inserted in the first opening  324 , the top protrusion  302  would fit within the first opening  324 , and the position of the solder notches  304  would correspond to (e.g., align with) the position of the solder pads  328 . Hence, by applying solder at the solder pads  328  across the width of the first opening  324  through the corresponding solder notches  304 , the solder pads  328  can be mechanically and electrically interconnected to the corresponding solder notches  304 . 
     Similarly, proximate to the second opening  326 , one more solder pads  330  can be provided on the top surface  322  of the top printed circuit board  320 . The one or more solder pads  330  facilitate electrical as well as mechanical interconnection between the second side printed circuit board inserted into the second opening  326 . For example, if the side printed circuit board  300  were inserted in the second opening  326 , the top protrusion  302  would fit within the second opening  326 , and the position of the solder notches  304  would correspond to (e.g., align with) the position of the solder pads  330 . Hence, by applying solder at the solder pads  330  across the width of the second opening  326  and through the corresponding solder notches  304 , the solder pads  330  can be mechanically and electrically interconnected to the corresponding solder notches  304 . 
       FIG. 3C  is a perspective view of a bottom printed circuit board  340  according to one embodiment of the invention. The bottom printed circuit board  340  includes a bottom (i.e., underside) surface  342 . As illustrated in  FIG. 3C , the bottom surface  342  is shown while the top surface of the bottom printed circuit board  340  is hidden. The bottom printed circuit board  340  includes a first opening  344  for receiving the first side printed circuit board, and a second opening  346  for receiving the second side printed circuit board. 
     One more solder pads  348  can be provided on the bottom surface  342  of the bottom printed circuit board  340 , proximate to the first opening  344 . The one or more solder pads  348  facilitate electrical as well as mechanical interconnection between the first side printed circuit board inserted into the first opening  344 . For example, if the side printed circuit board  300  were inserted in the first opening  344  from a top surface of the bottom printed circuit board  340 , the bottom protrusion  306  would fit within the first opening  344 , and the position of the solder pads  308  would respectively correspond to (e.g., align with) the position of the solder pads  348 . Hence, by applying solder at the solder pads  348  across or adjacent the first opening  344 , the solder pads  348  can be mechanically and electrically interconnected to the corresponding solder pads  308 . 
     One more solder pads  350  can be provided on the bottom surface  342  of the bottom printed circuit board  340 , proximate to the second opening  346 . The one or more solder pads  350  facilitate electrical as well as mechanical interconnection between the second side printed circuit board inserted into the second opening  346 . For example, if the side printed circuit board  300  were inserted in the second opening  346  from a top surface of the bottom printed circuit board  340 , the bottom protrusion  306  would fit within the second opening  346 , and the position of the solder pads  308  would respectively correspond to (e.g., align with) the position of the solder pads  350 . Hence, by applying solder at the solder pads  350  across or adjacent the second opening  346 , the solder pads  350  can be mechanically and electrically interconnected to the corresponding solder pads  350 . 
     The various printed circuit boards can include electrical components mounted on the printed circuit boards. Examples of electrical components are capacitors, resistors, inductors, transistors, and integrated circuit chips. One or both of these sides of any of the printed circuit boards can include electrical components mounted thereto. Besides electrical components, the various printed circuit boards typically also include metal (e.g., cooper, aluminum, solder) traces or solder connections. 
       FIGS. 4A and 4B  are perspective views of an assembled electronic device  400  according to one embodiment of the invention.  FIG. 4A  is a top perspective view of an assembled electronic device  400  according to one embodiment of the invention, and  FIG. 4B  is a bottom perspective view of the assembled electronic device  400  as illustrated in  FIG. 4A . 
     The assembled electronic device  400  includes a multi-part printed circuit board arrangement that includes a top printed circuit board  402 , a bottom printed circuit board  404 , a left printed circuit board  406 , and a right printed circuit board  408 . Each of the printed circuit boards  402 - 408  can have electrical components attached. In this embodiment, the bottom printed circuit board  404  is a primary printed circuit board. The left printed circuit board  406  and the right printed circuit board  408  are attached to the bottom printed circuit board  404 . The top printed circuit board  402  is also attached to the left printed circuit board  406  and the right printed circuit board  408 . 
     The attachment of the printed circuit board provides mechanical support as well as electrical connection between the printed circuit boards. A protrusion  409  of the left side printed circuit board  406  can extend through an opening in the top printed circuit board  402  and have solder pads (e.g., solder pads  306 ) on the protrusion  408  (e.g., protrusion  306 ) soldered to solder pads  410  provided on the top surface of the top printed circuit board  402 . A protrusion  412  of the right side printed circuit board  408  can extend through an opening in the top printed circuit board  402  and have solder notches (e.g., solder notches  304 ) on the protrusion  412  (e.g., protrusion  302 ) soldered to solder pads  414  provided on the top surface of the top printed circuit board  402 . 
     Each of the printed circuit boards  402 - 408  can have electrical components attached. One or both of these sides of any of the printed circuit boards can include electrical components mounted thereto. Examples of electrical components are capacitors, resistors, inductors, transistors, and integrated circuit chips. For example, the bottom printed circuit board  404  includes at least resisters  416 , capacitors  418 , transistors  420 , inductors  422 , and integrated circuit packages  424 . The left side printed circuit board  406  can include similar components, such as integrated circuit packages  426 . The right side printed circuit board  408  can also include similar components, such as integrated circuit packages  428 . Besides electrical components, the various printed circuit boards typically also include metal (e.g., cooper, aluminum, solder) traces, solder connections, metal wires and/or metal leads. 
     The bottom printed circuit board  404  illustrated in  FIG. 4B  is substantially larger than the top printed circuit board  402  illustrated in  FIG. 4A . Also, the left and right printed circuit boards  406  and  408  are also relatively small such that in the assembled electronic device  400  is compact. By providing the multi-part printed circuit board arrangement, the area required for the assembled electronic device  400  is reduced. As a result, the assembled electronic device  400  is a high density assemble that can be particularly compact. 
     The assembled electronic device  400  also has an electrical connector  430 . In the embodiment illustrated in  FIGS. 4A and 4B , the top printed circuit board  402  and the left and right printed circuit boards  406  and  408  are substantially adjacent the electrical connector  430 , e.g., a peripheral bus connector, that forms part of the assembled electronic device  400 . For example, the electrical connector  430  can be a Universal Serial Bus (USB) connector. The electrical connector  430  can be attached to the bottom printed circuit board  404 . A bracket  432  can be used to attached or support the electrical connector  430  with respect to the bottom printed circuit board  404 . Additionally, in the embodiment illustrated in  FIGS. 4A and 4B , the multi-part printed circuit board arrangement is formed around the electrical connector  430 . As a result, the printed circuit board arrangement can be compactly provided around an electrical connector. 
     The bottom printed circuit board  404  illustrated in  FIG. 4B  is substantially larger than the top printed circuit board  402  illustrated in  FIG. 4A . Also, the left and right printed circuit boards  406  and  408  are also relatively small such that in the assembled electronic device  400  is compact. By providing the multi-part printed circuit board arrangement, the area required for the assembled electronic device  400  is reduced. For example, as illustrated in  FIGS. 4A and 4B , the top printed circuit board  402  and the left and right printed circuit boards  406  and  408  are substantially adjacent the electrical connector  430 . 
       FIGS. 5A-5C  are perspective views of an electronic device  500  according to one embodiment of the invention. The electronic device  500  in this embodiment is a portable power adapter. The portable power adapter can be plugged into an electrical outlet. The portable power adapter can receive AC power from the electrical outlet and convert it into DC power. The DC power can then be made available to another electronic device that can couple to the portable power adapter. 
       FIG. 5A  illustrates a side perspective view of the electronic device  500 . The electronic device  500  includes a device housing  502 . As an example, the assembled electronic device  400  illustrated in  FIGS. 4A and 4B  can be provided internal to the device housing  502 . A first end of the device housing  502  is configured to receive a removable cap  504  (removable end cap). With the removable cap  504  removed, the assembled electronic device  400  can be inserted into the device housing  502 . In  FIG. 5A  the removable cap  504  is illustrated as being attached to the device housing  502 . The removable cap  504  includes or supports a first plug  506  and a second plug  508 . As illustrated, the plugs  506  and  508  are of a European configuration, however various other configurations are equally possible, including the U.S. configuration. The plugs  506  and  508  can be inserted into a power outlet (e.g., AC outlet). The plugs  506  and  508  can respectively include metal tips  510  and  512  which facilitate electrical connection when inserted into the power outlet. A second end  514  includes an electrical connector  516  that facilitates electrical connection with another device. When the electronic device  500  is a portable power adapter, the electrical connector  516  serves to provide power from the portable power adapter to another device that is electrically connected to the electrical connector  516 . As one example, the electrical connector  516  can pertain to a USB connector. 
       FIG. 5B  illustrates a first end perspective view of the electronic device  500 . The removable cap  504  is illustrated attached to the device housing  502 . The plugs  506  and  508  of the removable cap  504  are illustrated projecting outward from the removable cap  504 . The plug  506  and  508  can have an exterior non-conductive shell (e.g., plastic) with an inner metal conductor that electrically connects the metal tips  510  and  512  to the assembled electronic device within the device housing  502 . 
       FIG. 5C  illustrates a second end perspective view of the electronic device  500 . The electrical connector  516  is accessible from an opening  518  in the second end  514 . 
     Another aspect of the invention pertains to a clip for use in electronic device assemblies. The clip provides mechanical and electrical interconnection between two electrical structures, such as a contact pin and an electrical substrate (e.g., printed circuit board), that are coupled together as parts of an electronic device assembly. The clip also enables the mechanical and electrical interconnection to remain removable without substantial effort, which facilitates not only assembly but also repair of the electronic device. 
       FIGS. 6A-6D  are views of a clip  600  according to one embodiment of the invention.  FIG. 6A  is a perspective view of the clip  600 .  FIG. 6B  is a front view of the clip  600 .  FIG. 6C  is a rear view of the clip  600 .  FIG. 6D  is a side view of the clip  600 . The clip  600  can, for example, be used in the assembly of an electronic device, such as a power adapter. 
     The clip  600  is a metal clip. The clip  600  can be formed from a metal such as brass, copper or aluminum. The clip  600  includes a base portion  601  having a front surface  602  and a rear surface  604 . The clip  600  also includes a clip portion  605  having a first upper flexure  606 , a second upper flexure  608  and a lower flexure  610 . 
     The clip  600  can be use to facilitate mechanical and electrical connection between different electrical components of the electronic device. For example, the clip  600  can facilitate electrical connection between a printed circuit board and a contact pin. The upper flexures  606 ,  608  are biased towards the lower flexure  610  so that an edge (e.g., side) of the printed circuit board can be received between the upper flexures  606 ,  608  and the lower flexure  610 . The biasing facilitates securing the printed circuit board to the clip  600 . Also, since the clip  600  is metal and electrically conductive, the flexures  606 ,  608  and  610   610  can also make electrical contact with the printed circuit board while received between the upper flexures  606 ,  608  and the lower flexure  610  of the clip  600 . Hence, the flexures  606 ,  608  and  610  of the clip  600  can provide both mechanical and electrical connection with a substrate, such as a printed circuit board. 
     An alignment notch  612  can be provided in the clip  600  to facilitate alignment of the clip  600  with respect to a housing portion for the electronic device. Further, the clip  600  includes an opening  614  in the base portion. As discussed below, the opening  614  is able to receive a contact pin of a power adapter. When the contact pin is provided within the opening  614 , the clip  600  is mechanically and electrically coupled to the contact pin. The inner surface of the opening  612  can include a plurality of tabs  616 . The tabs  616  (e.g., interference tabs) can serve to secure the contact pin within the opening  612 , e.g., by mechanical interference. 
     In one example, the housing portion for electronic device is a portion of a housing for the electronic device. In one embodiment, the housing portion is a removable cap. For example, the electronic device can pertain to a power adapter which has a base housing and a removable cap. The removable cap can have at least one contact pin that extends therethrough. While the contact pin extends outward from an outer surface the removable cap, the clip  600  can be used to secure the contact pin against an inner surface of the removable cap. The clip  600  also facilitates electrical connection between the contact pin and a printed circuit board to be provided within the base housing for the power adapter. Still further, the clip  600  provides a mechanical connection to the printed circuit board. Since the clip  600  uses flexures  606 ,  608  and  610  to provide the electrical and mechanical coupling with a printed circuit board, the clip  600  (and thus the removable cap) remain removable from the printed circuit board (as well as the base housing). 
     As shown in  FIG. 6D , each of the first upper flexure  606  and the second upper flexure  608  can have a flared end  616 , and the lower flexure  610  can have a flared end  618 . The flared ends  616  and  618  facilitate receiving of a printed circuit board between the upper flexures  606 ,  608  and the lower flexure  610 . Additionally, the first upper flexure  606  and the second upper flexure  608  can each have a contact region  620  that can serve to make contact with an upper surface of a printed circuit board when the printed circuit board has been inserted between the upper flexures  606 ,  608  and the lower flexure  610 . The lower flexure  610  can also have a contact region  622  that can serve to make contact with a lower surface of the printed circuit board when the printed circuit board has been inserted between the upper flexures  606 ,  608  and the lower flexure  610 . 
     Although the clip  600  includes two upper flexures and one lower flexure, it should be noted that in other embodiments, the number of upper and lower flexures can vary. Hence, in general, a clip according to embodiments of the invention can include at least one upper flexure and at least one lower flexure. 
       FIG. 6E  is a flow diagram of an assembly process  650  for an electronic device according to one embodiment of the invention. The assembly process  650  can represent assembly of a portion of an electronic device that includes a contact pin external to a housing. As an example, the housing can pertain to a power adapter. 
     The assembly process  650  can provide  652  a housing portion for an electronic device being assembled. At least one contact pin can be inserted  654  into an opening in the housing portion. A clip can then be attached  656  to the at least one contact pin. The clip provides electrical coupling and can secure the at least one contact pin to the housing portion. Next, the housing portion can be attached  658  to a housing body of the electronic device. 
     As an example, the housing portion can be a removable end piece (e.g., removable cap) of a device housing (i.e., housing body) of the electronic device. The removable end piece can have an opening that receives a contact pin. The contact pin can be inserted into the opening and then secured in place with a clip, such as the metal clip illustrated in  FIGS. 6A-6D . Thereafter, the removable end piece with the opening having the contact pin and the clip can be attached to the device housing of the electronic device. When the removable end piece is attached to the device housing, the clip can mechanically and electrically couple (e.g., removably attach) with a printed circuit board provided within the device housing. The clip can include flexures that are mechanically biased so that the printed circuit board can be removably coupled (both mechanically and electrically) to the clip by way of the flexures. 
     Still another aspect of the invention pertains to a removable cap for an electronic device housing and a method for forming such a removable cap. In one implementation, the electronic device can pertain to a power adapter, and the removable cap can have one or more plugs integrally formed therewith. The one or more plugs can also have metal tips that can be attached. In one implementation, the metal tips are respectively removably attached to the one or more plugs. In one embodiment, the removable cap can be molded in longitudinal direction to have improved cosmetics, e.g., avoid parting lines or seams from forming in undesired portions. For example, the removable cap (including the plugs) can be molded in a longitudinal direction with the metal tips removed, and subsequent to molding the metal tips can be attached to the ends of the plugs. In  FIGS. 7A ,  7 B,  8 A and  8 B, a removable cap according to one embodiment is further described below. 
       FIGS. 7A and 7B  are perspective views of a removable cap  700  according to one embodiment of the invention. The removable cap  700  is, for example, suitable for use as the removable cap  504  illustrated in  FIGS. 5A and 5B . The removable cap  700  includes an inner side  702  and an outer side  704 . The inner side  702  includes a recess  706  about the periphery of the removable cap  700 . The inner surface  702  also includes features  708  that facilitate attachment of the removable cap  700  to a device housing (e.g., device housing  502 ). The outer side  704  includes plugs  710  and  712 . The plugs  710  and  712  can be integrally formed with the outer side  704  (as well as the inner side  702 ). Internal to the plugs  710  and  712  are metal pins  714  and  716 , respectively. The metal pin  714  extends internally through the plug  710  and through an opening in the outer side  704  and the inner side  702 , and the metal pin  716  extends internally through the plug  712  and through an opening in the outer side  704  and the inner side  702 . Thus, the metal pins  714  and  716  are exposed at the inner side  702  of the removable cap  700 . The metal pins  714  and  716  are also exposed at the outer side  704  (at the ends of the plugs  710  and  712 ) and can contain threads  718  and  720 , respectively. A metal tip  722  can be attached to the exposed portion of the metal pin  714  using the threads  718 , and a metal tip  724  can be attached to the exposed portion of the metal pin  716  using the threads  720 . In  FIG. 7A , the metal tips  722  and  724  are respectively removed from the metal pins  714  and  716 . In  FIG. 7B  the metal tips  722  and  724  are respectively attached to the metal pins  714  and  716 . In other embodiment, the metal tips  722  and  724  can be attached to the metal pins  714  and  716  using other than through using of mating threads. For example, the metal tips  722  and  724  can be glued, snapped, press-fix, formed, etc. to the metal pins  714  and  716 . 
       FIGS. 8A and 8B  are partial perspective views illustrating attachment of a printed circuit board  800  to a removable cap  802  of a device housing according to one embodiment of the invention. More particularly,  FIG. 8A  is a partial side perspective view of an assembly within the device housing, and  FIG. 8B  is a partial bottom perspective view of the assembly illustrated in  FIG. 8A . The illustrations in  FIGS. 8A and 8B  are shown with the device housing (e.g., device housing  502 ) removed. A metal clip  804  is affixed to the removable cap  802 . The metal clip  804  is, for example, the metal clip  600  illustrated in  FIGS. 6A-6D . The metal clip  600  includes a clip portion having first and second upper flexures  806  and a lower flexure  808 . The metal clip  804  attaches to the printed circuit board  800  by receiving the printed circuit board  800  between the upper flexures  806  and the lower flexure  808 , thereby establishing mechanical and electrical interconnection of the printed circuit board  800  and the removable cap  802 . An internal feature  810  can serve to align and secure the metal clip  804  with respect to the inner surface of the removable cap  802 . The removable cap  802  has at least one external plug  812  having an internal conductive post  814  (or pin) that extends through the external plug  812  and has an inner exposed end of the internal conductive post  814 . The metal clip  804  includes an opening for receiving and securing itself to the inner exposed end. When the inner exposed end of the internal conductive post  814  is provided in the opening to the metal clip  804 , the internal conductive post  814  is electrically connected to the printed circuit board  800  via the metal clip  804 . When the printed circuit board  800  is received between the upper flexures  806  and the lower flexure  808 , solder pads or traces  816  provided on the surface of the printed circuit board  800  can be adjacent the corresponding flexure, thereby providing electrical interconnection. By subsequently removing the removably cap  802  from its device housing, the printed circuit board  800  can be separated from the removable cap  802  without disassembly of soldered electrical connections, which facilitates maintenance and repair of the assembled electronic device. 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     The advantages of the invention are numerous. Different embodiments or implementations may, but need not, yield one or more of the following advantages. One advantage of certain embodiments of the invention is that high density electronic device assemblies can be formed and used within compact electronic device housings. Another advantage of certain embodiments of the invention is that substrate arrangements, metal clips, and/or removable housing portions can be used in forming high density electronic device assemblies and/or compact electronic device housings. 
     The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Metadata:
Filing Date: 20090623
Publication Date: 20150113
Grant Date: 20150113
Priority Date: 20081223
Inventors: LIN WEY-JIUN
PAN KEVIN
DE LA CRUZ CONRADO SACLUTI
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K1/141", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R9/091", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/145", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/57", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/09181", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/048", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6675", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/366", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/111", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/58", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/111", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/048", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/57", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/09181", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6675", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/366", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/145", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/141", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49117", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49117", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49002", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/58", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/111", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/6675", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/366", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/57", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/09181", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/145", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/048", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/141", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 42266778