PATENT DOCUMENT

Publication Number: US-9105899-B2
Application Number: US-201213607014-A
Country: US
Kind Code: B2

Title: Electronic device subassemblies

Abstract:
An electronic device may include subassemblies such as battery structures, electromagnetic shielding structures, and button structures. The electromagnetic shielding structures may include a conductive fence and a flexible shielding layer that covers electronic components. The electromagnetic shielding structure may be formed with a recess that receives a protruding portion of a battery. The recess may be formed from a multi-level shielding structure that includes rigid and flexible portions. The button structures may be mounted to a ledge that is formed as an integral part of a device housing. An electronic device battery may be enclosed in a protective battery sleeve. The battery sleeve may include a center portion that encloses the battery and peripheral portions that are folded and coupled to the center portion by adhesive material interposed between opposing surfaces of the folded peripheral portions and the center portion of the battery sleeve.

Claims:
What is claimed is: 
     
       1. A printed circuit board, comprising:
 a substrate; 
 an electronic component mounted to the substrate, wherein the electronic component has a first height; 
 a conductive fence surrounding the electronic component on the substrate, wherein the conductive fence has a second height that is lower than the first height; and 
 a flexible electromagnetic shielding layer that covers the electronic component and the conductive fence. 
 
     
     
       2. The printed circuit board defined in  claim 1  wherein the flexible electromagnetic shielding layer comprises a layer of metal foil. 
     
     
       3. The printed circuit board defined in  claim 1  wherein the flexible electromagnetic shielding layer comprises a layer of conductive fabric. 
     
     
       4. The printed circuit board defined in  claim 1  wherein the conductive fence comprises a metal fence. 
     
     
       5. The printed circuit board defined in  claim 1  wherein the flexible electromagnetic shielding layer is coupled to the conductive fence by a layer of adhesive material. 
     
     
       6. The printed circuit board defined in  claim 1  wherein the flexible electromagnetic shielding layer is coupled to the conductive fence by solder. 
     
     
       7. The printed circuit board defined in  claim 1  wherein the fence includes protruding ledges to which the flexible electromagnetic shielding layer is attached. 
     
     
       8. The printed circuit board defined in  claim 7  wherein the protruding ledges include upper and lower surfaces and wherein the flexible electromagnetic shielding layer is attached to the upper surface of the protruding ledges. 
     
     
       9. The printed circuit board defined in  claim 7  wherein the protruding ledges include upper and lower surfaces and wherein the flexible electromagnetic shielding layer is attached to the lower surface of the protruding ledges. 
     
     
       10. The printed circuit board defined in  claim 9  wherein the flexible electromagnetic shielding layer is attached to the lower surface of the protruding ledges by a welded connection through a sacrificial metal layer on a portion of the flexible electromagnetic shielding layer. 
     
     
       11. The printed circuit board defined in  claim 1  further comprising:
 an additional electronic component mounted to the substrate having a third height that is lower than the second height, wherein conductive fence surrounds the additional electronic component and wherein the flexible electromagnetic shielding layer covers the additional electronic component. 
 
     
     
       12. The printed circuit board defined in  claim 11  wherein the fence includes a first fence portion having the third height and a second fence portion having the second height. 
     
     
       13. An electronic device, comprising:
 a battery; 
 circuitry; and 
 an electromagnetic shielding structure having a recess that receives a portion of the battery, wherein the electromagnetic shielding structure encloses the circuitry. 
 
     
     
       14. The electronic device defined in  claim 13  wherein the electromagnetic shielding structure comprises a shielding layer that covers the circuitry, wherein the shielding layer includes a flexible portion that forms part of the recess and a rigid portion. 
     
     
       15. The electronic device defined in  claim 14  wherein the flexible portion comprises a conductive fabric. 
     
     
       16. The electronic device defined in  claim 14  wherein the flexible portion comprises a metal foil. 
     
     
       17. The electronic device defined in  claim 14  wherein the electromagnetic shielding structure further comprises a conductive fence that surrounds the circuitry, wherein the rigid portion is coupled to the conductive fence and wherein the flexible portion is attached to the rigid portion and the conductive fence. 
     
     
       18. The electronic device defined in  claim 17  wherein the rigid portion of the shielding layer includes at least one opening that is covered by the flexible portion of the shielding layer and wherein the portion of the battery that is received by the recess comprises a protruding portion of the battery. 
     
     
       19. The electronic device defined in  claim 18  wherein the circuitry includes an electronic component within the opening of the rigid portion of the shielding layer and wherein the electronic component is covered by the flexible portion of the shielding layer. 
     
     
       20. An electronic device, comprising:
 a switch; 
 a button member operable to actuate the switch; 
 a housing having an integral ledge to which the switch is mounted. 
 
     
     
       21. The electronic device defined in  claim 20  wherein the housing comprises a metal housing and wherein the integral ledge comprises a machined ledge formed from a portion of the metal housing. 
     
     
       22. The electronic device defined in  claim 21  further comprising a bracket mounted to the machined ledge, wherein the switch is mounted to the bracket. 
     
     
       23. The electronic device defined in  claim 22  wherein the housing includes an opening that faces the machined ledge and wherein the button member protrudes from the electronic device through the opening in the housing. 
     
     
       24. The electronic device defined in  claim 23  wherein the machined ledge includes a trench and wherein the bracket includes a protruding portion that mates with the trench. 
     
     
       25. The electronic device defined in  claim 21  wherein the bracket is mounted to the machined ledge by a screw. 
     
     
       26. Electronic device battery structures, comprising:
 a battery; and 
 a protective battery sleeve having a center portion that encloses the battery and folded peripheral portions that are coupled to the center portion by adhesive material interposed between opposing surfaces of the folded peripheral portions and the center portion. 
 
     
     
       27. The electronic device battery structures defined in  claim 26  wherein the adhesive material interposed between the opposing surfaces of the folded peripheral portions and the center portion comprises adhesive tape. 
     
     
       28. The electronic device battery structures defined in  claim 26  wherein the adhesive material interposed between the opposing surfaces of the folded peripheral portions and the center portion comprises glue. 
     
     
       29. The electronic device battery structures defined in  claim 26  wherein the adhesive material interposed between the opposing surfaces of the folded peripheral portions and the center portion comprises a pressure sensitive adhesive. 
     
     
       30. The electronic device battery structures defined in  claim 26  wherein the folded peripheral portions of the protective battery sleeve surround the center portion of the protective battery sleeve.

Description:
BACKGROUND 
     This relates generally to electronic devices, and more particularly, to electronic device subassemblies. 
     Electronic devices such as computers, media players, cellular telephones, and other portable electronic devices often include mechanical and electronic components such as buttons, batteries, and wireless circuitry. For example, cellular telephone transceiver circuitry and wireless local area network circuitry may allow a device to wirelessly communicate with external equipment. Antenna structures may be used in transmitting and receiving associated wireless signals. A battery may be used to provide power for an electronic device. 
     It can be challenging to incorporate components such as wireless circuitry and batteries on an electronic device. Space is often at a premium, particularly in compact devices such as portable electronic devices. The components such as the battery and device circuitry may be constrained. In addition, the presence of metal in device components and on printed circuit boards may affect antenna performance. If care is not taken, antenna structures may not perform satisfactorily or components may consume more space within an electronic device than desired. It may also be difficult to provide adequate structural support for mechanical components such as buttons in compact designs. 
     It would therefore be desirable to be able to provide improved electronic device subassemblies in an electronic device. 
     SUMMARY 
     An electronic device may include subassemblies such as battery structures, electromagnetic shielding structures, and button structures. 
     The electromagnetic shielding structures may be used to electromagnetically shield circuitry on a printed circuit substrate. The circuitry may include one or more electronic components mounted to the substrate. The electronic components may have different heights. The electromagnetic shielding structures may include a conductive fence that surrounds some of the electronic components. A flexible electromagnetic shielding layer may be used to cover the electronic components and the conductive fence. The flexible electromagnetic shielding layer may be a metal foil, conductive fabric, or formed from other flexible shielding materials. One or more of the components that are covered by the shielding layer may be taller than the surrounding fence and may be accommodated by flexing of the shielding layer. 
     The flexible electromagnetic shielding layer may be attached to the conductive fence via adhesives, solder, welds, or other connections. For example, the electromagnetic shielding layer may be welded to the fence using a sacrificial layer of metal that helps to protect the shielding layer from damage during welding operations. 
     The electromagnetic shielding structure may be formed as a multi-level shielding structure with a recess that receives a portion of a battery (e.g., a protruding portion of the battery). The multi-level shielding structure may include rigid and flexible portions. The multi-level shielding structure may include a shielding layer attached to a conductive fence to cover electronic components. The flexible portion of the multi-level shielding structure may form part of the recess. The rigid portions may include openings that are covered by the flexible portion of the shielding structure. Electronic components that are taller than surrounding rigid portions of the shielding structure may be positioned within the openings and accommodated by the flexible portions of the shielding structure that covers the openings. 
     The electronic device may include button structures. The button structures may include a switch and a button member that may be pressed to actuate the switch. The switch may be mounted to a ledge of the housing via a bracket. The ledge may be formed as an integral part of the housing. For example, the ledge may be a machined ledge formed as an integral portion of the housing. The housing may include an opening through which the button member protrudes from the electronic device. The opening may face the housing ledge. The housing ledge may include a trench that mates with a corresponding protruding portion of the bracket to help ensure that the position of the switch and bracket is maintained relative to the position of the opening in the housing. 
     The battery of the electronic device may be enclosed in a protective battery sleeve. The battery sleeve may include a center portion that encloses the battery and peripheral portions that are folded and coupled to the center portion by adhesive material interposed between opposing surfaces of the folded peripheral portions and the center portion of the battery sleeve. The folded peripheral portions may surround the center portion of the battery sleeve. 
     Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device in accordance with an embodiment of the present invention. 
         FIG. 2  is a schematic diagram of an illustrative electronic device having circuitry and a battery in accordance with an embodiment of the present invention. 
         FIG. 3  is a perspective view of electronic device circuitry including electronic components that are enclosed by electromagnetic shielding structures in accordance with an embodiment of the present invention. 
         FIG. 4  is a cross-sectional side view of electromagnetic shielding structures including a fence and a flexible shielding layer attached to the fence in accordance with an embodiment of the present invention. 
         FIG. 5  is a cross-sectional side view of electromagnetic shielding structures including a fence and a flexible shielding layer attached to the underside of protruding ledges of the fence in accordance with an embodiment of the present invention. 
         FIG. 6  is a cross-sectional side view of electromagnetic shielding structures including a fence and a flexible shielding layer attached to exterior surfaces of the fence in accordance with an embodiment of the present invention. 
         FIG. 7  is a cross-sectional side view of electromagnetic shielding structures including a fence and multiple shielding layers attached to the fence in accordance with an embodiment of the present invention. 
         FIG. 8  is a cross-sectional side view of electromagnetic shielding structures including a fence and a shielding layer attached to the fence by a welded connection through a sacrificial layer in accordance with an embodiment of the present invention. 
         FIG. 9  is a perspective view of electromagnetic shielding structures including a fence having segments with different heights in accordance with an embodiment of the present invention. 
         FIG. 10  is a cross-sectional side view of electromagnetic shielding structures having a recess that accommodates a battery in accordance with an embodiment of the present invention. 
         FIG. 11  is a perspective view of electromagnetic shielding structures including a fence and a shielding layer having openings that may be covered by additional shielding layers in accordance with an embodiment of the present invention. 
         FIG. 12  is a perspective view of electromagnetic shielding structures having a recess that accommodates a protruding portion of a battery in accordance with an embodiment of the present invention. 
         FIG. 13  is a cross-sectional side view of button structures that are structurally supported by a housing ledge in accordance with an embodiment of the present invention. 
         FIG. 14  is a perspective view of a device housing having a button opening and an opposing integral housing ledge in accordance with an embodiment of the present invention. 
         FIG. 15  is a perspective view of a switch bracket having a protruding member that may mate with an integral housing ledge in accordance with an embodiment of the present invention. 
         FIG. 16  is a perspective view of a battery sleeve that encloses a battery showing how peripheral portions of the battery sleeve may be folded and attached to a center portion of the battery sleeve in accordance with an embodiment of the present invention. 
         FIG. 17  is a diagram of illustrative steps that may be performed to attach peripheral portions of a battery sleeve to a center portion of the battery sleeve in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     An electronic device such as a portable (e.g., mobile) electronic device or other compact electronic device may include subassemblies having mechanical and electronic components. 
     An illustrative electronic device is shown in  FIG. 1 . Electronic device  10  may be a portable electronic device or other suitable electronic device. For example, electronic device  10  may be a laptop computer, a tablet computer, a somewhat smaller device such as a wrist-watch device, pendant device, headphone device, earpiece device, or other wearable or miniature device, a cellular telephone, a media player, etc. 
     Device  10  may include a housing such as housing  12 . Housing  12 , which may sometimes be referred to as a case, may be formed of plastic, glass, ceramics, fiber composites, metal (e.g., stainless steel, aluminum, etc.), other suitable materials, or a combination of these materials. In some situations, parts of housing  12  may be formed from dielectric or other low-conductivity material. In other situations, housing  12  or at least some of the structures that make up housing  12  may be formed from metal elements. 
     Device  10  may, if desired, have a display such as display  14 . Display  14  may, for example, be a touch screen that incorporates capacitive touch electrodes. Display  14  may include image pixels formed from light-emitting diodes (LEDs), organic LEDs (OLEDs), plasma cells, electronic ink elements, liquid crystal display (LCD) components, or other suitable image pixel structures. A cover glass layer may cover the surface of display  14 . 
     The cover glass layer that covers display  14  may have openings such as a circular opening for button  16  and a speaker port opening such as speaker port opening  18  (e.g., for an ear speaker for a user). Device  10  may also have other openings (e.g., openings in display  14  and/or housing  12  for accommodating volume buttons, ringer buttons, sleep buttons, and other buttons, openings for an audio jack, data port connectors, removable media slots, etc.). For example, openings in housing  12  may accommodate buttons  16  such as volume buttons. 
     Housing  12  may include a peripheral conductive member such as a bezel or band of metal that runs around the rectangular outline of display  14  and device  10  (as an example). The peripheral conductive member may be used in forming the antennas of device  10  if desired. Antennas may be located along the edges of device  10 , on the rear or front of device  10 , as extending elements or attachable structures, or elsewhere in device  10 . 
     An illustrative schematic diagram of an electronic device  10  is shown in  FIG. 2 . As shown in  FIG. 2 , electronic device  10  may include electronic device circuitry  21  and battery  40 . Electronic device circuitry  21  may include storage and processing circuitry  22 , input-output circuitry  24 , and other components such as components  36 . 
     Storage and processing circuitry  22  may be configured to execute software that controls the operation of device  10 . Processing circuitry  22  may include microprocessor circuitry, digital signal processor circuitry, microcontroller circuitry, application-specific integrated circuits, and other processing circuitry. Storage circuitry  22  may include storage such as volatile and non-volatile memory, hard-disk storage, removable storage, solid state drives, random-access memory, memory that is formed as part of other integrated circuits such as memory in a processing circuit, etc. 
     Input-output circuitry  24  may include components for receiving input from external equipment and for supplying output from device  10 . For example, input-output circuitry  24  may include wireless communications circuitry  26 . Wireless communications circuitry  26  may be used for transmitting and/or receiving signals in one or more communications bands such as cellular telephone bands, wireless local area network bands (e.g., the 2.4 GHz and 5 GHz IEEE 802.11 bands), satellite navigation system bands, etc.). 
     As an example, wireless communications circuitry  26  may include radio-frequency transceivers, impedance matching circuitry, filter circuitry, switches, and other circuits implemented using one or more components such as integrated circuits, discrete components (e.g., capacitors, inductors, and resistors), surface mount technology (SMT) components, or other electrical components. Antenna structures  30  may include inverted-F antennas, patch antennas, loop antennas, monopoles, dipoles, or other suitable antennas. 
     Sensors  32  may include an ambient light sensor, a proximity sensor, touch sensors such as a touch sensor array for a display and/or touch buttons, pressure sensors, temperature sensors, accelerometers, gyroscopes, and other sensors. 
     Buttons  16  may include sliding switches, push buttons, menu buttons, buttons based on dome switches, keys on a keypad or keyboard, or other switch-based structures. 
     Display  14  may be a liquid crystal display, an organic light-emitting diode display, an electrophoretic display, an electrowetting display, a plasma display, or a display based on other display technologies. 
     Device  10  may also contain other components  36  (e.g., communications circuitry for wired communications, status indicator lights, vibrators, etc.). Components  36  may include circuitry such as clock generation circuitry or power supply circuitry. 
     Battery  40  may provide power for electronic device circuitry  21 . For example, battery  40  may include battery cells sealed within a battery sleeve. The battery sleeve may be formed from sheets of foil, plastic, or other desired materials. The battery cells may, as an example, include lithium-ion cells or other desired types of battery cells. 
     Some of electronic device circuitry  21  may be sensitive to electromagnetic interference. For example, wireless communications circuitry  26  may include wireless transceivers that are sensitive to radio-frequency interference from other circuitry such as clock generation or power supply circuitry. Some of electronic device circuitry  21  may produce radio-frequency interference (e.g., a cellular transceiver may emit radio-frequency signals that interfere with operation of other components of device  10  that are sensitive to radio-frequency interference). To help ensure that the circuitry of device  10  operates properly, it may be desirable to provide electromagnetic shielding structures for some or all of the components of device  10 . 
       FIG. 3  is an illustrative diagram of electronic device circuitry  21  that may include shielding structures  42 . As shown in  FIG. 3 , electronic device circuitry  21  may include one or more electronic components  46  formed on a printed circuit substrate  44  (e.g., a printed circuit board). Electronic components  46  may include circuitry such as communications circuitry  26 , sensors  32 , or other electronic device circuitry. As an example, components  46  may be surface-mount technology (SMT) components that are mounted directly onto printed circuit substrate  44 . Components  46  may include integrated circuit components and discrete components such as discrete capacitors, inductors, resistors, etc. 
     Printed circuit substrate  44  may be formed from rigid printed circuit board materials such as fiberglass-filled epoxy (e.g., FR4), flexible printed circuits (e.g., printed circuits formed from flexible sheets of polymer such as polyimide), and rigid flex circuits (e.g., printed circuits that contain both rigid portions and flexible tails). 
     Shielding structures  42  may be formed using electromagnetic shielding materials and/or insulating materials. For example, shielding materials used to form shielding structures  42  may include conductive materials such as metals (e.g., copper, aluminum, etc.), metal alloys, conductive adhesives, conductive paint (e.g., silver paint, platinum paint, etc.), metal foil, solder, or other desired electromagnetic shielding materials. Shielding materials  18  may be formed in various configurations including walls, fences, sheets, layers, combinations of these configurations, or other desired arrangements. For example, shielding materials  18  may be used to form a fence that surrounds components  46  and a lid that covers the fence. Shielding structures  42  may cover or enclose one or more components  46  (e.g., components that generate electromagnetic interference or are sensitive to electromagnetic interference). If desired, electronic device circuitry  21  may be provided with multiple shielding structures  42  that shield respective portions of circuitry  21 . 
     Insulating materials used to form shielding structures  42  may help prevent electrical shorting between shielding materials of structure  42  and conductive materials such as conductive portions of components  46 . The insulating materials may be formed from dielectric materials such as plastics or other desirable materials that provide electrical insulation. 
     Components  46  of electronic device circuitry  21  may have different physical dimensions. For example, some components may be taller than other components or may occupy a larger footprint on printed circuit substrate  44 . It may be challenging to provide shielding structures  42  for shielding multiple components having different physical dimensions. For example, shielding structures  42  that are insufficiently tall may be damaged by contact with components. As another example, shielding structures  42  that are sufficiently tall to cover each of the components may leave gaps between the shielding structures  42  and relatively short components, which may result in inefficient use of available space in a compact electronic device. 
       FIG. 4  is an illustrative cross-sectional side view of shielding structures  42  for electronic device circuitry  21 . As shown in  FIG. 4 , shielding structures  42  may include fences  52  and shielding layer  54  that covers underlying components  46 A,  46 B, and  46 C. Fences  52  may surround components  46 A,  46 B, and  46 C. Fences  52  may have height H 1  and may be formed from any desired shielding material. Fences  52  may provide structural support for shielding layer  54 . For example, fences  52  may be formed from metal or other conductive materials. Shielding layer  54  may be attached to fences  52  via connections  56 . Fences  52  may include protruding ledges  55  to which shielding layer  54  may be attached via connections  56 . Connections  56  may include solder joints, laser welds, conductive adhesives, or any desired connections. Connections  56  may be formed between protruding ledges  55  of fences  52  and shielding layer  54 . 
     Shielding layer  54  may be formed from a flexible shielding material. For example, shielding layer  54  may be formed from a metal foil (e.g., aluminum foil, copper foil, etc.), a metal coating on a sheet of dielectric, or may be formed from a conductive fabric such as a woven conductive fabric. Conductive fabrics used to form shielding layer  54  may include fabrics formed from metal fibers or fibers that are coated with a conductive material (e.g., metal). For example, fibers such as plastic fibers, glass fibers, carbon fibers, organic fibers, inorganic fibers, fibers formed from other materials, and fibers formed from two or more of these materials may be coated with a conductive material to form a conductive fabric. If desired, shielding layer  54  may be formed from other materials such as stainless steel or metal alloys. 
     Shielding layer  54  may accommodate components  46  of various heights while providing electromagnetic shielding for the components. In the example of  FIG. 4 , components  46 A,  46 B, and  46 C may be shielded by shielding structures  42 . Components  46 A,  46 B, and  46 C may have respective heights H 2 , H 3 , and H 4 . Heights H 2  and H 3  of components  46 A and  46 B may be less than height H 1  of fence  52 , whereas height H 4  of component  46 C may be greater than height H 1 . Flexible shielding layer  54  may flex to accommodate height H 4  of component  46 C while maintaining an overall slim profile. 
     If desired, an optional layer of insulating material  58  may be interposed between shielding layer  54  and components such as component  46 C. Insulating layer  58  may be formed from insulating materials such as dielectric materials. For example, insulating layer  58  may be formed from an adhesive polymer layer such as polyimide that is attached to the underside of shielding layer  54 . Insulating layer  58  may serve to help prevent electrical shorting between conductive materials of shielding layer  54  and components such as component  46 C. 
     The example of  FIG. 4  in which shielding layer  54  is attached to a top surface of protruding ledges  55  is merely illustrative. If desired, shielding layer  54  may be attached to the underside (e.g., a bottom surface) of protruding ledges  55  of fences  52  as shown in  FIG. 5 . By attaching shielding layer  54  to the underside of protruding ledges  55 , the overall volume of shielding structures  42  may be further reduced. 
     The examples of  FIG. 4  and  FIG. 5  in which shielding layer  54  is attached to either a top surface or a bottom surface of protruding ledges  55  is merely illustrative. If desired, fences  52  may be formed without any protruding ledges as shown in  FIG. 6 . Fences  52  may be formed vertically and may have opposing inner and outer surfaces (e.g., inner surfaces that face the interior of shielding structures  42  and outer surfaces that face the exterior of shielding structures  42 ). In the example of  FIG. 6 , shielding layer  54  is attached to the outer surfaces of fences  52 . However, shielding layer  54  may be attached to the inner surfaces of fences  52 , or may be attached to a combination of inner and outer surfaces of fences  52  (as examples). 
     Shielding structures  42  may include covers formed from multiple shielding layers.  FIG. 7  is an illustrative cross-sectional diagram showing shielding structures  42  having shielding layers  62 ,  64 , and  66  that cover components  46 A,  46 B, and  46 C. Shielding layers  62  and  66  may be attached to fences  52  via connections  56 . Shielding layers  62  and  66  may extend horizontally to cover components such as components  46 A and  46 B that have sufficiently low heights (e.g., the height of fences  52  may be greater than or equal to the heights of components  46 A and  46 B). 
     Components such as component  46 C may have heights that exceed the height of fences  52  and may be covered by additional shielding layer  64  that is attached to shielding layers  62  and  66  via connections  56 . The thickness T of layers  62  and  66  may be added to the height of fences  52  to provide sufficient clearance between additional shielding layer  64  and component  46 C. In other words, the height of additional shielding layer  64  (e.g., the distance between shielding layer  64  and substrate  44 ) may be greater than the height of component  46 C. 
     In scenarios such as when shielding structures  42  are formed from a shielding layer  54  that is welded to fences  52  (e.g., via laser welding), it may be desirable to provide structures  42  with sacrificial regions. For example, to help reduce the total height of shielding structures  42 , shielding layers  54  may be formed from a thin layer of metal foil (e.g., a metal foil layer that is less than 150 μM). In this scenario, sacrificial metal layers may be used to help prevent damage to shielding layers  54  during laser welding operations. 
       FIG. 8  is an illustrative cross-sectional diagram showing how shielding structures  42  may be provided with sacrificial layers  72  that cover regions of shielding layer  54  over protruding portions  55  of fences  52 . Sacrificial layers  72  may be formed from metal or other sacrificial materials. For example, metal may be plated onto portions of shielding layer  54  to form sacrificial layers  72 . Connections  56  may be formed using sacrificial layers  72  and shielding layer  54 . During welding operations such as laser welding, sacrificial layers  72  may help prevent shielding layer  54  from being damaged while connections  56  are made. 
     The example of  FIG. 8  in which shielding layer  54  is formed on bottom surfaces of protruding ledges  55  is merely illustrative. If desired, shielding layer  54  may be formed on top surfaces of fences  52  using sacrificial layers (regions)  72  that cover portions of shielding layer  54 . 
     Shielding structures  42  may be formed with fences  52  that conform to the dimensions and locations of components  46  that are surrounded by fences  52 .  FIG. 9  is an illustrative perspective view of electronic device circuitry  21  having shielding structures  42  with fences  52  that conform to components  46 . As shown in  FIG. 9 , fence  52  may include trench  82  that accommodates relatively short components  46  while helping to minimize total volume of shielding structures  42 . In other words, fence  52  may include portions  84  at a first height that accommodates relatively tall components  46  and portion  86  that accommodates relatively short components  46 . A shielding layer  54  that conforms to the structure of fences  52  may be formed over components  46 . 
     Shielding structures that conform to dimensions of underlying components may be used to help provide more efficient utilization of available space in electronic devices.  FIG. 10  is an illustrative cross-sectional diagram showing how shielding structures  42  of electronic device circuitry  21  may be provided with a recess that accommodates protruding portions of battery  40 . 
     As shown in  FIG. 10 , shielding structures  42  may conform to the dimensions of underlying components  46 . Components  46  may be placed (e.g., mounted) on printed circuit substrate  44  in an arrangement such that shorter components are located at the periphery of printed circuit substrate  44 , whereas taller components are centrally located. Shielding structures  42  may include shielding layers  92  and  94 . Shielding layer  92  may cover relatively tall components (e.g., centrally located components), whereas shielding layer  94  may cover relatively short components (e.g., peripherally located components). Shielding layer  92  may be formed from a rigid shielding material such as a rigid metal layer. For example, shielding layer  92  may be formed from a metal lid attached to fences such as fences  52  of  FIG. 9 . 
     In region  96  of shielding structures  42 , an opening may be formed in shielding layer  92 . A flexible shielding layer  94  may be attached to rigid shielding layer  92  to cover the opening in region  96 . Flexible shielding layer  94  may, for example, be formed from flexible conductive materials such as metal foil, dielectric material coated with metal, conductive fabric, etc. Flexible shielding layer  94  may be attached to rigid shielding layer  92  via connection  56  and may extend across the opening in region  96  of shielding structures  42  to fence  98 . Fence  98  may be somewhat shorter than fences such as fence  52 . For example, fence  52  may conform to the height of components  46  that are covered by flexible shielding layer  94 . 
     Shielding layers  92  and  94  may combine to form multi-level shielding structures  42  that accommodates various component dimensions (e.g., shielding layer  92  may form an upper level of shielding structures  42  whereas shielding layer  94  may form a lower level of shielding structures  42 ). Recess  102  may be formed by forming shielding layer  94  at a lower height than shielding layer  92 . Recess  102  may be used to accommodate protruding region  104  of battery  40 . Protruding region  104  may provide battery  40  with additional capacity and help to improve battery life of device  10  without increasing the overall size of device  10  (e.g., by efficiently using available space within device  10 ). 
     Shielding layer  92  may be formed over openings in a lower level of shielding structures  42 .  FIG. 11  is an illustrative perspective view of electronic device circuitry  21  with shielding structures  42  having an upper level  112  and a lower level  114 . Upper level  112  may cover relatively tall components  46  (e.g., components that are taller than lower level  114 ), whereas lower level  114  may be used to shield other components  46  (e.g., relatively short components formed at the periphery of substrate  44 ). 
     Openings  116  may be formed in lower level  114  to accommodate one or more components  46  that are taller than lower level  114  but not sufficiently tall as to require placement within upper level  112 . In some scenarios, manufacturing tolerances may require that sufficient clearance be provided between components  46  and the interior surfaces of rigid portions of shielding structures  42 . For example, a minimum distance may be required between the top surfaces of components  46  and the interior surface of rigid portions of lower level  114  to help ensure that variance in the height of components  46  or lower level  114  does not result in undesired contact between components  46  and the rigid portions lower level  114  (e.g., contact that could potentially damage lower level  114  or components  46 ). 
     The example of  FIG. 11  in which openings  116  are formed in lower level  114  is merely illustrative. If desired, openings such as openings  116  may be similarly formed in upper level  112  (e.g., to accommodate components  46  having heights that exceed the height of upper level  112 ). 
     Openings  116  may be covered by shielding layers such as flexible shielding layers.  FIG. 12  is an illustrative perspective view showing how openings  116  may be covered by shielding layer  94 . Shielding layer  94  may be formed from a flexible material such as metal foil or conductive fabric. Shielding layer  94  may be attached to portions of shielding structure  112  via connections such as connections  56  ( FIG. 10 ). As shown in  FIG. 12 , protruding portion  104  of battery  40  may be accommodated by recess  102  of shielding structures  42  (e.g., a recess formed by dividing shielding structures  42  into multiple levels). 
     Electronic devices may include buttons that can be actuated (e.g., by a user). The buttons may include button members that are pressed to actuate corresponding switches. It may be challenging to manufacture buttons in electronic devices. For example, due to manufacturing tolerances, it may be difficult to precisely mount switches relative to corresponding button members. Button members may also be subject to excessive force that is applied to the button members (e.g., by users). 
     Buttons in an electronic device may be structurally supported using portions of an electronic device housing.  FIG. 13  is an illustrative cross-sectional diagram of electronic device  10  having button  16  that is structurally supported by a portion of electronic device housing  12 . 
     As shown in  FIG. 13 , button  16  may include switch  124  and a button member  122  that can be pressed to actuate switch  124 . For example, button member  122  may be pressed by a user so that button member  122  contacts and actuates switch  124 . Button member  122  may be formed from any desired material such as plastic, metal, or other materials. For example, button member  122  may be machined or die-cast from metals or metal alloys such as aluminum, copper, etc. Switch  124  may be formed from any desired type of switch. For example, switch  124  may be a dome switch. In this scenario, the dome switch may be compressed when button member  128  is pressed, which shorts metal contacts in the dome switch and actuates the dome switch. 
     Housing  12  may include opening  127  that accommodates button member  122 . Button member  122  may include flange portions  128  that help prevent button member  122  from passing through opening  127 . Flange portions  128  may help to maintain the position of button member  122  within housing  122 . 
     Switch  124  may be mounted to bracket  126 . Bracket  126  may be formed from metal. For example, metal bracket  126  may be machined or die-cast from metals or metal alloys. Metal bracket  126  may be mounted to ledge  130  of housing  12 . In the example of  FIG. 13 , bracket  126  is mounted to ledge  130  using one or more screws  128 . 
     Housing ledge  130  may be formed as an integral portion of housing  12 . For example, ledge  130  may be formed from a block of metal such as aluminum that is also used to form housing  12 . Machining tools (e.g., cutting tools, milling tools, grinding tools, computer-controlled machining tools etc.) may be used to form ledge  130  as an integral portion of housing  12 . Integral housing ledge  130  formed using machining tools may sometimes be referred to herein as a machined ledge. 
     Ledge  130  may help reduce variability in the structure of button  16  (e.g., variance associated with manufacturing tolerances of tools used to form button  16 ). In the example of  FIG. 13 , ledge  130  is formed at a distance L 1  from side wall  129  of housing  12  in which opening  127  is formed. Because ledge  130  is formed as an integral part of housing  12 , distance L 1  may be relatively insensitive to manufacturing tolerances. Button member  122  may abut side wall  129  and include flange portion  128  having width L 2  (i.e., button member  122  may extend from side wall  129  at a distance L 2 ). Bracket  126  may extend from ledge  130  at a distance L 3 . Distances L 2  and L 3  may have minimal variance, because button member  128  and bracket  126  may be formed using manufacturing techniques such as molding or die-casting having minimal variance. The remaining gap between button member  128  and bracket  128  may have a distance L 4  that is determined by the difference between L 1  and the sum of L 2  and L 3 . Distance L 4  may also have minimal variance, because distances L 1 , L 2 , and L 3  have minimal variance and the locations of button member  122  and bracket  126  are substantially fixed by housing side wall  129  and housing ledge  130 . 
     Housing ledge  130  may serve as a stable structural support for bracket  126  and switch  124 . When button member  122  is pressed, force may be transferred from button member  122  to ledge  130  via switch  124  and bracket  126 . Button member  122  and bracket  126  may be maintained in a stable position even in scenarios in which excess force is applied to button member  122  (e.g., by a user), because the excess force may be transferred to housing  12  via integral housing ledge  130 . 
     If desired, housing ledge  130  may be formed with a recess that mates with a protruding portion of bracket  126 .  FIG. 14  is an illustrative perspective view of a housing  12  with an integral housing ledge  130  having recess  142 . Ledge  130  may oppose button opening  127  in side wall  129  of housing  12 . Recess  142  may be formed from housing ledge  130  using tools such as machining tools (e.g., computer-controlled machining tools). For example, recess  142  may be formed simultaneously with ledge  130  from housing  12  or may be formed subsequent to machining ledge  130 . 
       FIG. 15  is an illustrative underside perspective view of a bracket  126  having a protruding portion  144  for mating with recess  142  of housing ledge  130  ( FIG. 14 ). Protruding portion  144  is shown in the example of  FIG. 15  as substantially rectangular, but may be formed having any desired shape. Protruding portion  144  of bracket  126  may mate with recess  142  of ledge  130  to help prevent undesired movement of bracket  126  and switch  124  relative to opening  127  of side wall  129 . If desired, protruding portion  144  may be used in combination with one or more screws  128  as shown in  FIG. 13 . 
     The example of  FIGS. 13 ,  14 , and  15  in which switch  124  is mounted to bracket  126  is merely illustrative. If desired, multiple switches  124  may be mounted to bracket  126 . For example, multiple openings in side wall  127  of  FIG. 14  may be formed to accommodate multiple button members  122 . In this scenario, each button member may mate with a corresponding switch that is mounted to bracket  126 . 
     A battery such as battery  40  in electronic device  10  may be enclosed in a protective sleeve.  FIG. 16  is an illustrative perspective view of a protective sleeve  152  that encloses battery  40 . Protective sleeve  152  may be sealed around the periphery of battery  40 . For example, peripheral regions  154  around battery  40  may be sealed to protect battery  40 . Protective sleeve  152  may include contacts such as contacts  155  for conveying battery signals (e.g., to electronic device circuitry). 
     To help reduce the footprint of battery  40 , peripheral regions  154  of sleeve  152  may be folded inward (e.g., towards battery  40 ) as shown by arrows  156 . Peripheral regions  154  may be attached to center portion  158  of sleeve  152  without increasing the combined height of battery  40  and sleeve  152 . 
       FIG. 17  is a cross-sectional diagram of illustrative steps that may be performed to attach peripheral regions  154  of battery sleeve  152  to center portion  158 . A battery  40  enclosed in a battery sleeve  152  may be initially provided at step  162 . 
     During the operations of step  166 , an adhesive layer  164  may be deposited over peripheral regions  154  of battery sleeve  152 . Adhesive layer  164  may be formed from an insulating material. Adhesive layer  164  may, for example, include a layer of tape formed from an insulating material such as polyimide or other insulating materials. 
     During the operations of step  168 , an additional adhesive material  170  may be deposited over the upper surface of peripheral regions  154 . Adhesive material  170  may include tape, glue, or other adhesive materials. Adhesive material  170  may be formed from insulating materials. As examples, adhesive material  170  may include double-sided tape or pressure-sensitive adhesives. 
     During the operations of step  172 , peripheral regions  154  of battery sleeve  152  may be folded upwards to center portion  158  of sleeve  152 . Peripheral regions  154  may be attached to center portion  158  via adhesive materials  170  and  164 . Adhesive materials  170  and  164  may be interposed between opposing surfaces  176  and  174  of center portion  158  and peripheral regions  154 , respectively. By attaching peripheral regions  154  to center portion  158  using adhesive materials  170  and  164  that are interposed between opposing surfaces  174  and  176 , the footprint of battery sleeve  152  may be reduced without increasing combined height H of sleeve  152  and battery  40 . 
     The example of  FIG. 17  in which multiple adhesive layers are used to attach peripheral regions  154  to center portion  158  of battery sleeve  152  is merely illustrative. If desired, one or more adhesive layers may be used to attach peripheral regions  154  to center portion  158  without increasing combined height H. 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20120907
Publication Date: 20150811
Grant Date: 20150811
Priority Date: 20120907
Inventors: PAKULA DAVID A.
SANFORD EMERY A.
MANULLANG TYSON B.
MONTEVIRGEN ANTHONY S.
MERZ NICHOLAS G. L.
WERNER CHRISTOPHER M.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K1/0243", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01M50/284", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/224", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/202", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K9/0032", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2200/30", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10371", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0277", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2/1022", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K1/0243", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/224", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/284", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M50/202", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/0243", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01L2924/19105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/3025", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y02E60/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/19105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0277", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01M2200/30", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L2924/3025", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01M2200/30", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K9/0032", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0277", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10371", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K9/0032", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10371", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 50233092