PATENT DOCUMENT

Publication Number: US-10787014-B2
Application Number: US-201816127043-A
Country: US
Kind Code: B2

Title: Thermally conductive structure for dissipating heat in a portable electronic device

Abstract:
This application relates to a portable electronic device. The portable electronic device includes an operational component capable of generating heat and walls that define a cavity capable of carrying the operational component. The portable electronic device further includes a support plate that is welded to at least one of the walls. The support plate includes a thermally conductive layer that is thermally coupled to the operational component, where the thermally conductive layer includes a first material that is capable of conducting at least some of the heat away from the electronic component. The support plate further includes a first stiffness promoting layer that is welded to the thermally conductive layer, where the first stiffness promoting layer includes a second material having sufficient material hardness for welding the support plate to at least one of the walls such as to increase a stiffness of the support plate.

Claims:
What is claimed is: 
     
       1. A portable electronic device, comprising:
 an enclosure that defines a cavity, the enclosure comprising a metal wall; 
 an operational component located in the cavity, the operational component capable of generating thermal energy; 
 a support plate located in the cavity and joined to the metal wall, the support plate comprising:
 a thermally conductive core that is thermally coupled to the operational component, the thermally conductive core comprising a first surface and a second surface that is opposite the first surface, 
 a first stiffening layer coupled with the thermally conductive core at the first surface, wherein the operational component is located on the first stiffening layer, and 
 a second stiffening layer coupled with the thermally conductive core at the second surface, wherein the thermally conductive core includes a first thermal conductivity, and wherein each of the first stiffening layer and the second stiffening layer include a second thermal conductivity that is less than the first thermal conductivity; and 
 
 a display assembly secured with the enclosure, wherein the operational component is positioned between the display assembly and the first stiffening layer. 
 
     
     
       2. The portable electronic device of  claim 1 , wherein the operational component comprises a camera system. 
     
     
       3. The portable electronic device of  claim 1 , wherein the thermally conductive core includes at least one of copper or aluminum, and wherein each of the first stiffening layer and the second stiffening layer includes at least one of stainless steel, molybdenum, or titanium. 
     
     
       4. The portable electronic device of  claim 1 , wherein the operational component comprises a power supply. 
     
     
       5. The portable electronic device of  claim 1 , further comprising a back wall coupled to the metal wall, wherein the back wall comprises a non-metal material. 
     
     
       6. The portable electronic device of  claim 5 , wherein the first stiffening layer includes a first thickness, and wherein the second stiffening layer is equivalent to the first thickness. 
     
     
       7. The portable electronic device of  claim 1 , wherein the thermally conductive core separates the first stiffening layer from the second stiffening layer such that the first stiffening layer is free of contact from the second stiffening layer. 
     
     
       8. A portable electronic device, comprising:
 an enclosure comprising a glass back wall and a metal band that combines with the glass back wall to that define a cavity; 
 an operational component that generates thermal energy within the cavity; 
 a support plate that (i) is thermally coupled to and joined to the metal band, and (ii) carries the operational component, wherein the support plate includes:
 a stiffening layer, wherein the operational component is located on the stiffening layer, 
 a thermally conductive core that is overlaid by the stiffening layer, wherein the thermally conductive core defines a directional path by which the thermal energy received by the thermally conductive core is conducted away from the operational component, and 
 a thermal insulation layer that is overlaid by the thermally conductive core, wherein the thermal insulation layer prevents the thermal energy received by the thermally conductive from passing through the glass back wall. 
 
 
     
     
       9. The portable electronic device of  claim 8 , wherein the thermal insulation layer is positioned between the thermally conductive core and the glass back wall. 
     
     
       10. The portable electronic device of  claim 8 , wherein the thermal insulation layer comprises a first thickness, and wherein the thermally conductive core comprises a second thickness that is greater than the first thickness. 
     
     
       11. The portable electronic device of  claim 8 , wherein the metal band comprises stainless steel. 
     
     
       12. The portable electronic device of  claim 8 , wherein the operational component comprises a camera system or a power supply. 
     
     
       13. The portable electronic device of  claim 8 , wherein the support plate has a thickness, and the thermal insulation layer has a thickness that accounts for no more than about 50% of the thickness of the support plate. 
     
     
       14. The portable electronic device of  claim 8 , wherein the thermally conductive core includes at least one of aluminum, copper, or molybdenum. 
     
     
       15. A portable electronic device, comprising:
 an operational component that generates heat; 
 walls that define a cavity, wherein the operational component is carried within the cavity; 
 a support plate that carries and is overlaid by the operational component, the support plate being thermally coupled to and joined to the walls, the support plate including:
 a thermally conductive core capable of conducting the heat away from the operational component and towards the walls, 
 a first metal layer secured with the thermally conductive core, and 
 a second metal layer secured with the thermally conductive core, wherein the first metal layer is free of contact with the second metal layer based on the thermally conductive core; and 
 
 a display assembly secured with the walls, wherein the operational component is positioned between the display assembly and the first metal layer. 
 
     
     
       16. The portable electronic device of  claim 15 , wherein the first metal layer and the second metal layer include cladded stainless steel. 
     
     
       17. The portable electronic device of  claim 15 , wherein the first metal layer and the second metal layer are welded to opposing surfaces of the thermally conductive core. 
     
     
       18. The portable electronic device of  claim 15 , wherein a shape of the thermally conductive core is substantially maintained while the thermally conductive core conducts the heat away from the operational component. 
     
     
       19. The portable electronic device of  claim 15 , wherein the operational component comprises a power supply. 
     
     
       20. The portable electronic device of  claim 15 , wherein the operational component comprises a circuit.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims the benefit of U.S. Provisional Application No. 62/557,090, entitled “PORTABLE ELECTRONIC DEVICE,” filed Sep. 11, 2017, which is incorporated by reference herein in its entirety for all purposes. 
     This patent application is also related and incorporates by reference in their entirety each of the following patent applications: 
     (i) U.S. Patent Provisional Application No. 62/681,499 entitled “CLADDED METAL STRUCTURES FOR DISSIPATION OF HEAT IN A PORTABLE ELECTRONIC DEVICE” by COUNTS et al. filed Jun. 6, 2018; 
     (ii) U.S. patent application Ser. No. 16/127,055 entitled “PLATE FOR MAGNETIC SHIELDING OF AN OPERATIONAL COMPONENT IN A PORTABLE ELECTRONIC DEVICE” by WAH et al. filed Sep. 10, 2018; 
     (iii) U.S. patent application Ser. No. 16/127,064 entitled “STRUCTURES FOR SECURING OPERATIONAL COMPONENTS IN A PORTABLE ELECTRONIC DEVICE” by RAMMAH et al. filed Sep. 10, 2018; 
     (iv) U.S. patent application Ser. No. 16/127,071 entitled “SPACE-EFFICIENT FLEX CABLE WITH IMPROVED SIGNAL INTEGRITY FOR A PORTABLE ELECTRONIC DEVICE” by SLOEY et al. filed Sep. 10, 2018; and 
     (v) U.S. patent application Ser. No. 16/126,984 entitled “SUBSTRATE MARKING FOR SEALING SURFACES” by HAWTHORNE et al. filed Sep. 10, 2018. 
    
    
     FIELD 
     The described embodiments relate generally to a support structure for carrying an operational component within a portable electronic device. More particularly, the described embodiments relate to the support structure including a thermally conductive core for dissipating thermal energy generated by the operational component. 
     BACKGROUND 
     Recent technological advances have enabled manufacturers to include a large number of operational components (e.g., processors, antennas, displays, cameras, haptic feedback components, etc.) in a small cavity of an enclosure of a portable electronic device. However, due to the small cavity and the heat generated by these operational components, the portable electronic device may experience a sustained elevated operating temperature. Consequently, the elevated operating temperature can lead to inefficient performance and premature failure of these operational components. Accordingly, there is a need for support structures that are capable of effectively dissipating the heat generated by these operational components. 
     SUMMARY 
     This paper describes various embodiments that relate to a support structure for carrying an operational component within a portable electronic device. In particular, the various embodiments relate to the support structure including a thermally conductive core for dissipating thermal energy generated by the operational component. 
     According to some embodiments, a portable electronic device is described. The portable electronic device includes an operational component that generates heat, a housing having walls that define a cavity capable of carrying the operational component within the cavity, and a support plate that is joined to one of the walls. The support plate includes a thermally conductive layer that carries and is in thermal contact with the operational component, where the thermally conductive layer includes a first material that is capable of conducting at least some of the heat away from the operational component, and a layer that stiffens the support plate, the layer including a second material. 
     According to some embodiments, an enclosure for a portable electronic device is described. The enclosure includes walls that define a cavity, where the walls are capable of carrying an operational component that generates thermal energy within the cavity. The enclosure includes a support plate that (i) is thermally coupled to and joined to one of the walls, and (ii) supports the operational component. The support plate further includes a thermally conductive core that is in thermal contact with the operational component, where the thermally conductive core defines a directional path by which the thermal energy is conducted away from the operational component, and a thermal insulation layer that is in thermal contact with the thermally conductive core, where the thermal insulation layer is capable of conducting the thermal energy away from the wall joined to the support plate. 
     According to some embodiments, an enclosure for a portable electronic device, is described. The enclosure includes an operational component that generates heat, walls that define a cavity, the walls capable of carrying the operational component within the cavity, and a support plate that carries the operational component. The support plate includes a thermally conductive core formed of a first material having a first coefficient of thermal expansion, where the thermally conductive core is capable of conducting the heat away from the operational component, a first metal layer that overlays the thermally conductive core, and a second metal layer that is overlaid by the thermally conductive core, where the first and second metal layers include a second material having a second coefficient of thermal expansion that is less than the first coefficient of thermal expansion. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
     This Summary is provided merely for purposes of summarizing some example embodiments so as to provide a basic understanding of some aspects of the subject matter described herein. Accordingly, it will be appreciated that the above-described features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description, Figures, and Claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements. 
         FIGS. 1A-1B  illustrate perspective views of a portable electronic device that includes a support structure for dissipating thermal energy generated by an operational component, in accordance with some embodiments. 
         FIG. 2  illustrates a perspective view of a portable electronic device that includes a support structure for dissipating thermal energy generated by an operational component, in accordance with some embodiments. 
         FIGS. 3A-3C  illustrate various views of a portable electronic device that includes a support structure for dissipating thermal energy generated by an operational component, in accordance with some embodiments. 
         FIG. 4  illustrates a side view of a portable electronic device that includes a support structure for dissipating thermal energy generated by an operational component, in accordance with some embodiments. 
         FIG. 5  illustrates a cross-sectional view of a portable electronic device that includes a support structure for dissipating thermal energy generated by an operational component, in accordance with some embodiments. 
         FIG. 6  illustrates a cross-sectional view of a portable electronic device that includes a support structure for dissipating thermal energy generated by an operational component, in accordance with some embodiments. 
         FIGS. 7A-7F  illustrate cross-sectional views of a support structure for dissipating thermal energy generated by an operational component, in accordance with various embodiments. 
         FIGS. 8A-8B  illustrate various views of a portable electronic device that includes a support structure for dissipating thermal energy generated by an operational component, in accordance with some embodiments. 
         FIG. 9  illustrates a perspective view of a portable electronic device that includes a support structure for dissipating thermal energy generated by an operational component, in accordance with some embodiments. 
         FIG. 10  illustrates a flowchart for forming a support structure for a portable electronic device, in accordance with some embodiments. 
         FIG. 11  illustrates a system diagram of a portable electronic device that is capable of implementing the various techniques as described herein, in accordance with some embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Representative applications of methods and apparatus according to the present application are described in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The embodiments described herein relate generally to a support structure for a portable electronic device. In particular, the support structure includes a thermally conductive core for dissipating thermal energy generated by the operational component. As described herein, the term dissipation can refer to the transformation of mechanical energy into energy dissipation. The term thermal dissipation can also be referred to as thermal conduction. 
     Although recent technological advances have enabled portable electronic device manufacturers to fit a large combination of different operational components (e.g., processor, antenna, camera, sensor, etc.) within a single enclosure of a portable electronic device, the portable electronic device is consequently subject to operating at a sustained elevated operating temperature. As a result, these operational components may experience premature failure. Additionally, the sustained elevated operating temperature may be perceived by a user as heat as absorbed by walls of the enclosure where the user&#39;s fingers are placed to support the enclosure. 
     To cure the aforementioned deficiencies, the systems and techniques described herein relate to support structures for carrying these operational components. In particular, the support structures include a thermally conductive layer that is capable of conducting thermal energy away from these operational components. Furthermore, the support structures may include at least one stiffness promoting layer. The stiffness promoting layer may increase the rigidity of the support structure as well as enable the support structure to be welded to the enclosure, thereby preventing the operational components from becoming permanently misaligned such as when the portable electronic device is exposed to a load associated with a drop event (e.g., dropping the portable electronic device on a hard surface). In some examples, the stiffening promoting layer may also be referred to as a stiffening layer. 
     According to some embodiments, a portable electronic device is described. The portable electronic device includes an operational component capable of generating heat, a housing having walls that define a cavity capable of carrying the operational component, and a support plate that is joined to one of the walls. The support plate includes a thermally conductive layer that carries and is in thermal contact with the operational component, where the thermally conductive layer includes a first material that is capable of conducting at least some of the heat away from the operational component, and a stiffener that promotes stiffness of the support plate, where the stiffener includes a second material having a material hardness suitable for welding the support plate to the wall. 
     These and other embodiments are discussed below with reference to  FIGS. 1A-1B, 2, 3A-3C, 4-6, 7A-7F, 8A-8B, and 9-11 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. 
       FIGS. 1A-1B  illustrate a portable electronic device that includes support structures, in accordance with various embodiments. In particular, the support structures are capable of supporting operational components that are carried within a cavity of an enclosure of the portable electronic device. According to some examples, the portable electronic device can include a computing device, a smartphone, a laptop, a smartwatch, a fitness tracker, a mobile phone, a wearable consumer device, and the like. The enclosure of the portable electronic device can also be referred to as a housing. 
       FIG. 1A  illustrates a first perspective view of the portable electronic device  100 , where the portable electronic device  100  includes an enclosure  110  having walls that define a cavity (not illustrated), where one or more operational components are carried within the cavity. The enclosure  110  includes a top wall  112 -A, a bottom wall  112 -B, and side walls  112 -C. 
       FIG. 1A  illustrates that the portable electronic device  100  includes a display assembly  102  that covers a majority of a top surface of the enclosure  110 . The display assembly  102  can include a capacitive unit and/or a force detection unit that is capable of detecting an input at the display assembly  102  and presenting a corresponding graphical output at the display assembly  102 . In some embodiments, the display assembly  102  is overlaid by a protective cover  108 , where the protective cover  108  is secured with a trim structure  106 . In particular, the trim structure  106  may be joined to the enclosure  110  with an attachment feature, such as an adhesive, a weld, and the like. The protective cover  108  may prevent surface abrasions and scratches from damaging the display assembly  102 . The protective cover  108  may be formed from a transparent material, such as glass, plastic, sapphire, or the like. 
     In some embodiments, the top wall  112 -A may be separated from the bottom wall  112 -B by a dielectric material  116 -A, B, and the side walls  112 -C may be separated from the top wall  112 -A and the bottom wall  112 -B by the dielectric material  116 -A, B. The dielectric material  116 -A, B can include plastic, injection-molded plastic, polyethylene terephthalate (“PET”), polyether ether ketone (“PEEK”), ceramic, and the like. By incorporating the dielectric material  116 -A, B, the walls  112 -A, B, C are capable of being electrically isolated from each other. 
     According to some embodiments, the portable electronic device  100  includes a button  140  and a switch  142  that are carried along the side wall  112 -C. The bottom wall  112 -B includes a connector  120  that is capable of providing data and/or power to the portable electronic device  100 . In some examples, the connector  120  refers to a bus and power connector. 
     According to some embodiments, the portable electronic device  100  includes a notch  122  in proximity to the top wall  112 -A. As illustrated in  FIG. 1A , the notch  122  is defined by a cut-out of the protective cover  108 . The notch  122  includes one or more electronic components  124  (e.g., infrared detector, front-facing camera, etc.). In some examples, the one or more electronic components  124  may be utilized for facial recognition. It should be noted that the supporting structures described herein may be utilized to secure these electronic components  124  such as to prevent these electronic components  124  from becoming dislodged or misaligned when the portable electronic device  100  experiences a load event. 
     According to some examples, at least one of the top wall  112 -A, the bottom wall  112 -B, or the side wall  112 -C may be formed of material other than metal. Beneficially, the use of non-metal material can reduce the amount of electromagnetic interference associated with the enclosure  110  and a wireless transceiver that is carried within the enclosure  110 . Additionally, the use of non-metal material reduces the amount of parasitic capacitance between any metal support structures that are carried within the cavity and the enclosure  110 . According to some examples, the non-metal material includes glass, plastic, ceramic, and the like. Although non-metal material such as glass is beneficial in permitting electromagnetic waves to pass through the enclosure  110 , the glass is also more susceptible than metal to cracking or deforming when the portable electronic device  100  experiences a drop event. 
     According to some embodiments, the portable electronic device  100  carries one or more operational components within a cavity (not illustrated) of the portable electronic device  100 . These operational components may include a circuit board, an antenna, a multi-core processor, a haptic feedback module, a camera, a sensor, an IR detector, an inductive charging coil, and the like. It should be noted that the operational component can generate a large amount of thermal energy, e.g., between about 60 W-100 W of thermal energy. Indeed, circuits and processors are capable of generating a large amount of thermal energy due to constant switching of transistors. Because the operational component can generate a large amount of thermal energy (e.g., heat, etc.), the enclosure  110 , such as the side walls  112 -C can absorb a significant amount of the thermal energy which can render a feeling of discomfort when a user handles the portable electronic device  100 . Furthermore, generating a large amount of thermal energy may lead to increasing operating temperature within the portable electronic device  100 ; thus, leading to decreased operating performance and potential premature failure of components. 
     Additionally, the amount of the thermal energy that is absorbed by the enclosure  110  is further exacerbated by the materials of the enclosure  110 . In particular, the materials of the enclosure  110  may have a low rate of thermal conductivity. For example, the enclosure  110  can include one or more types of materials such as metal, polymers, glass, ceramic, and the like. In some examples, the metal can include at least one of a steel alloy, aluminum, aluminum alloy, titanium, zirconium, magnesium, copper, and the like. In some examples, the enclosure  110  can include a metal oxide layer that is formed from a metal substrate. 
       FIG. 1B  illustrates a second perspective view of the portable electronic device  100 , in accordance with some embodiments. As illustrated in  FIG. 1B , an operational component  150  is carried at least in part within a protruding trim structure  140 . The protruding trim structure  140  is disposed in proximity to a corner  108  of the enclosure  110 . In some examples, proximity may refer to the operational component  150  is a distance of less than about 50 mm from the corner  108 . As illustrated in  FIG. 1B , the operational component  150  is a camera system having dual lenses (e.g., wide and a telephoto, etc.). Additionally, the camera system may include a flash module. 
     As illustrated in  FIG. 1B , the protruding trim structure  140  is secured to and extends from a back wall  130  of the portable electronic device  100 . According to some examples, the back wall  130  is formed of a material other than metal. The non-metal material enables a magnetic field to pass through the enclosure  110  in order to charge wireless charging coils  160 , such as magnetic cores that include ferrites. 
       FIG. 2  illustrates a magnified perspective view of internal components of a portable electronic device  200 , in accordance with some embodiments. In particular,  FIG. 2  illustrates the portable electronic device  200  without a display assembly  102  and a protective cover  108 , thereby revealing a support plate  230 . According to some examples, the support plate  230  is capable of carrying at least one operational component  250  within a cavity  270  of the portable electronic device  200 . In some examples, the operational component  250  is capable of generating an amount of heat while the operational component  250  is performing a function. According to some embodiments, multiple operational components  250  may be carried along a top surface of the support plate  230 . In some examples, the operational component  250  can include a circuit board, a power supply unit (e.g., a battery, etc.), a camera system, a haptic feedback module, a sensor, an inductive charging coil, and the like. 
     As illustrated in  FIG. 2 , the support plate  230  is secured to the enclosure  110  of the portable electronic device  200 . In particular, at least one of the top wall  112 -A, the bottom wall  112 -B, or the side wall  112 -C is joined to the support plate  230 . According to some examples, the support plate  230  is joined to the enclosure  110  by a rail feature  240 . In particular, the rail feature  240  includes a first surface that is joined to a surface of the enclosure  110  and a second surface that is joined to the support plate  230 . In some examples, the first surface is generally orthogonal to the second surface. In other examples, the first surface is other than parallel to the second surface. According to some examples, the rail feature  240  is further joined to the support plate  230  and the enclosure  110  by at least one of a weld, a cladded structure, an adhesive, and the like. Beneficially, joining the support plate  230  to the enclosure  110  may increase the rigidity or stiffness of lateral ends of the support plate  230 . This may be beneficial in preventing the operational component that is carried by the support plate  230  from shifting and becoming misaligned when the enclosure  110  of the portable electronic device  200  is subject to a load as a result of a drop event. 
     As illustrated in  FIG. 2 , the operational component  250  is carried along a top surface of the support plate  230 . It should be noted that the support plate  230  does not intersect and/or overlap an inductive charging coil  160 . This is particularly beneficial if the support plate  230  includes a metal material which may adversely impact the ability of a magnetic field to pass through the enclosure  110  to reach the inductive charging coil  160 . Additionally, because the inductive charging coil  160  may generate an amount of heat during a charging operation, it may be preferable to not position the operational component  250  immediately adjacent to the inductive charging coil  160 . 
       FIG. 3A  illustrates a partial overhead view of internal components of a portable electronic device  300 , in accordance with some embodiments. In particular,  FIG. 3A  illustrates the portable electronic device  300  without a display assembly  102  and a protective cover  108 , thereby revealing a support plate  330  that is carried within a cavity of the enclosure  310 . According to some examples, the enclosure  310  may be formed of metal, such as stainless steel, aluminum, titanium, and the like such that the enclosure  310  functions as an active antenna. In some examples, the enclosure  310  includes different metal sections, such as a long arm section  312  and a short arm section  314  that are capable of transmitting and/or receiving high-frequency electromagnetic waves. 
     As illustrated in  FIG. 3A , the support plate  330  carries a camera system  350  and a power supply unit  360 . According to some examples, the power supply unit  360  and the camera system  350  may be separated from each other by a sufficient distance so as to minimize an amount of heat in any one region of the cavity. According to some examples, the portable electronic device  300  includes thermistors for detecting an operating temperature within the operating environment of the portable electronic device  300 . In response to determining that the current operating temperature exceeds a temperature threshold in any one region, a processor (not illustrated) may adjust the operating parameters (e.g., processing speed, increase cooling, etc.) of the portable electronic device  300  so as to prevent the current operating temperature from reaching an upper operating temperature limit. 
       FIG. 3B  illustrates a cross-sectional view of the portable electronic device  300  as taken along the A-A reference line of the portable electronic device  300  of  FIG. 3A , in accordance with some embodiments. As will be described in greater detail herein, the support plate  330  includes a thermally conductive core  324  so as to facilitate in limiting the current operating temperature of the portable electronic device  300  in any one region of the cavity. According to some examples, the thermally conductive core  324  is capable of dissipating thermal energy (e.g., heat) that is generated by the operational component(s)—e.g., the camera system  350  and the power supply unit  360 —away from these operational component(s). Beneficially, the thermally conductive core  324  spreads heat away from a single region, thereby preventing a “hot spot” from being created. Additionally, the thermally conductive core  324  is capable of more uniformly spreading the heat throughout the cavity of the portable electronic device  300  so as to limit the current operating temperature within the cavity and enable the operating components(s) to be run longer and more efficiently. 
     As illustrated in  FIG. 3B , the support plate  330  is joined to metal bands  312  of the portable electronic device  300 , where the metal bands  312  may correspond to a perimeter structure of the portable electronic device  300 . Specifically,  FIG. 3B  illustrates an upper stiffening layer  322 -A that overlays the thermally conductive core  324  and a lower stiffening layer  322 -B that is overlaid by the thermally conductive core  324 . According to some examples, the operational component(s) are secured to the upper stiffening layer  322 -A by at least one attachment feature (not illustrated) such as a weld, an adhesive, a fastener, and the like. Additionally, the support plate  330  may be joined to the metal bands  312  by an attachment feature such as a rail feature—e.g., the rail feature  240 , a weld, an adhesive, a fastener, an interlock feature, and the like. 
     According to some examples, the support plate  330  may include at least one of the upper stiffening layer  322 -A or the lower stiffening layer  322 -B. Additionally, the upper and lower stiffening layers  322 -A, B may be formed of different materials and may have different thicknesses in order to impart different stiffness properties. These aspects will be described in greater detail with reference to  FIGS. 6A-6F . 
     Notably, the upper and lower stiffening layers  322 -A, B provide an amount of stiffness for the support plate  330  not otherwise possible where the support plate  330  only includes the thermally conductive core  324 . In particular, stiffness of the support plate  330  is important because the support plate  330  is generally overlaid by the back wall  130  of the portable electronic device  100  and an adhesive. Because the enclosure  110  may not be a unibody structure due to the back wall  130  being formed of a different material than the walls of the enclosure  110 , there is a reduction in overall stiffness relative to a unibody metal enclosure. 
       FIG. 3C  illustrates an exemplary diagram of a cross-sectional heat map that corresponds to the cross-sectional view of the portable electronic device  300  of  FIG. 3B , in accordance with some embodiments. As illustrated in  FIG. 3C , the heat generated by the operational component(s)—e.g., the camera system  350  and the power supply unit  360 —is more uniformly spread throughout the cavity of the portable electronic device  300 . Additionally, the support plate  330  is capable of limiting the current operating temperature of the portable electronic device  300  so that it falls below a predetermined temperature threshold. 
     According to some embodiments, a shape/dimension of the thermally conductive core  324  may define a directional path by which the thermal energy is conducted away from the operational components—e.g., the camera system  350  and the power supply unit  360 . For example, if a thickness of the thermally conductive core  324  is greatest along the peripheral edges of the thermally conductive core  324  and thinnest along the medial line of the thermally conductive core  324 , then the thermally conductive core  324  may generate a thermal heat dissipation path that resembles an inverted bell curve. Additionally, shapes/dimensions of the upper and lower stiffening layers  322 —A, B may also contribute to the directional path by which the thermal energy is conducted away from the operational components. 
       FIG. 4  illustrates a side view of a portable electronic device  400 , in accordance with some embodiments. As illustrated in  FIG. 4 , the portable electronic device  400  includes an enclosure  110  that carries operational components within a cavity. The enclosure includes a protective cover  108  that is secured to a trim structure  106  that overlays an upper surface of the enclosure  110 . 
       FIG. 5  illustrates a cross-sectional view of a portable electronic device  500  as taken along the reference section B-B of the portable electronic device  400 , in accordance with some embodiments.  FIG. 5  illustrates that the portable electronic device  500  includes an enclosure  110  that corresponds to the side walls  112 -C of the portable electronic device  100 . The upper surface of the enclosure  110  supports a display assembly  510  that is secured by a trim structure  106 . Additionally, a protective cover  108  overlays the display assembly  510 . The enclosure  110  is joined to a perimeter structure  540 . Additionally, the enclosure is joined to a support plate  520 , where the support plate  520  overlays a back wall  530  of the portable electronic device  500 . In some examples, the support plate  520  is joined to the back wall  530  by an attachment feature  542  such as an adhesive. Although not illustrated in  FIG. 5 , the support plate  520  carries at least one operational component. 
     As illustrated in  FIG. 5 , the support plate  520  includes an upper stiffening layer  522 -A and a lower stiffening layer  522 -B that are separated by a thermally conductive core  524 . According to some embodiments, the support plate  520  is welded to the enclosure  110  and/or the perimeter structure  540 . In some examples, the upper stiffening layer  522 -A includes a cladded material, such as cladded stainless steel that provides sufficient stiffness for the portable electronic device  500  to hold the support plate  520 . Additionally, the lower stiffening layer  522 -B may include cladded stainless steel. In some examples, the upper and lower stiffening layers  522 -A, B are formed of stiffness-inducing materials such as stainless steel, titanium, molybdenum, and the like. Additionally, the upper and lower stiffening layers  522 -A, B may impart greater abrasion resistance and hardness to the support plate  520 , thereby also shielding the thermally conductive core  524  from abrasion. It should be noted that the material of the upper and lower stiffening layers  522 -A, B should be of sufficient hardness so that the support plate  520  can be joined to the enclosure  110  and/or the perimeter structure  540 . In some examples, the upper and lower stiffening layers  522 -A, B include at least one of copper (117 GPa), stainless steel (193 GPa), or cladded stainless steel (184 GPa) so as to impart the necessary amount of stiffness to weld the upper and lower stiffening layers  522 -A, B to the thermally conductive core  524 . 
     As illustrated in  FIG. 5 , the support plate  520  is cladded to the enclosure  110  at heat affected zones  580 -A. Additionally, the upper and lower stiffening layers  522 -A, B are cladded to the thermally conductive core  524  at heat affected zones  580 -B, C, respectively. The heat affected zones  580 -A, B, C can represent where cladding material (e.g., stainless steel, etc.) and the metal substrate (e.g., copper, copper alloy, aluminum alloy, etc.) melt and mix together to form a metallurgical bond. In some examples, the heat affected zones  580 -A, B, C are characterized as having a high degree of mixing between the cladding material and the metal substrate. In some examples, the cladding is performed by a laser cladding process. 
     In some examples, the thermally conductive core  524  is formed of a material having a high coefficient of thermal conductivity such as copper, aluminum, graphite, and the like. Although in some examples, it may be preferable to not use graphite because graphite is a frangible material that may be difficult to utilize as a structural element for supporting operational component(s). 
     According to some examples, the upper and stiffening layers  522 -A, B may have different thicknesses. Although it may be preferable to have symmetry in the thicknesses between the upper and lower stiffening layers  522 -A, B so as to prevent and/or minimize deformation of the thermally conductive core  524 , especially when the operating temperature of the thermally conductive core  524  is increased while conducting heat away from operational component(s). For instance, the coefficient of thermal conductivity of the material of the thermally conductive core  524  may be counteracted by the coefficient of thermal conductivity of the material of the upper and lower stiffening layers  522 -A, B. By implementing a tri-layer as illustrated in  FIG. 6 , the upper and lower stiffening layers  522 -A, B may serve to generally maintain the shape of the thermally conductive core  524 . In contrast, if the support plate  520  includes a single stiffening layer and the thermally conductive core  524 , then the thermally conductive core  524  may be more susceptible to deforming in shape. 
     According to some examples, the upper and lower stiffening layers  522 -A, B are characterized as having a thermal rate of conductivity that is less than the thermally conductive core  524 . Accordingly, the upper and lower stiffening layers  522 -A, B can function as a thermal barrier that prevents the thermal energy from being absorbed by the side walls  112 -C of the enclosure  110  while the thermally conductive core  524  functions as a thermal bridge. In particular, the thermal bridge creates a thermal path of least resistance for heat transfer from the operational component(s). 
     Furthermore, the lower stiffening layer  522 -B may function as a thermal insulation to prevent the thermal energy (e.g., heat) from spreading to the back wall  530 . Indeed, the lower stiffening layer  522 -B may trap most of the heat within the thermally conductive core  524 , thereby causing the heat to instead be spread by the thermally conductive core  524  laterally through the cavity  570  of the portable electronic device  500  (e.g., between the side walls  112 -C, between the top wall  112 -A and the bottom wall  112 -B, etc.) instead of vertically through the cavity  570  (i.e., top-down between the back wall  130  and the protective cover  108 ). Beneficially, by preventing the heat from spreading to the back wall  530 , the portable electronic device  500  prevents heat from prematurely wearing out the adhesive  542  as well as preventing a “hot spot” along the back wall where a user&#39;s hand may likely be in contact with the portable electronic device  500 . 
     Additionally, the upper and stiffening layers  522 -A, B may have a different thickness than the thermally conductive core  524 . According to some examples, the ratio between the upper stiffening layer  522 -A, the thermally conductive core  524 , and the lower stiffening layer  522 -B is about 1:2:1 (25%-50%-25%). It should be noted that these ratios are largely dependent upon the particular process for welding cladded stainless steel to the thermally conductive core  524 . Additionally, these ratios may be balanced in order to achieve an ideal combination of stiffness and thermal conductivity. 
     In some examples, the upper and lower stiffening layers  522 -A, B have an upper limit of thickness of about 60-70 microns. In some examples, the thermally conductive core  524  has a lower limit of thickness of about 35-50 microns. It should be noted that if the thermally conductive core  524  is less than about 35 microns thick, then the thermally conductive core  524  becomes less effective at dissipating heat from the operational component(s). In some examples, the thickness of the support plate  520  is between about 100 microns to about 500 microns. 
     Although  FIG. 5  illustrates that the upper and stiffening layers  522 -A, B separate the thermally conductive core  524 , it should be noted that the support plate  520  may also include the thermally conductive core  524  that corresponds to an exterior surface of the support plate  520 . In this particular embodiment, the thermally conductive core  524  may overlay a single stiffening layer. 
     Additionally, the support plate  520  may be used as a ground for the chassis for the portable electronic device  500 . In some examples, the support plate  520  is grounded together with the perimeter structure  540 , such as if the perimeter structure  540  is formed of metal. 
     According to some examples, the support plate  520  includes features to limit the amount of thermal energy that is conducted away from the operational component(s). For instance, the features may include parts, gaps or slots in the support plate ( 520 ) that are positioned in selective regions to minimize the amount of heat that is conducted away. Specifically, because the support plate  520  may be welded to the enclosure  110  and/or the perimeter structure  540 , the support plate  520  includes these features to minimize and/or prevent heat from conducting to the walls—e.g., the side walls  112 -C and prevent “hot spots” from generating along the surfaces of the enclosure  110  that are likely to come into contact with a user&#39;s hand. 
     According to some examples, the external surface of the support plate  520  may include multiple dots or specks as formed by a stippling process. Beneficially, the stippling process induces stress on the support plate  520  so as to minimize the material(s) of the support plate  520  from relaxing and causing deformation. Additionally, the stippling process is capable of controlling the flatness of the support plate  520 . 
       FIG. 6  illustrates a cross-sectional view of a portable electronic device  600  as taken along the reference section B-B of the portable electronic device  400 , in accordance with some embodiments. The portable electronic device  600  is similar to the portable electronic device  500  illustrated in  FIG. 5  except that the enclosure  110  includes a rail element  612  that protrudes from an inner surface of the enclosure  110 —e.g., the side wall  112 -C. The rail element  612  may be integrally formed with the enclosure  110  in some examples. As illustrated in  FIG. 6 , the rail element  612  overlays and is joined to an external surface of the support plate  520 , such as through a weld. In this manner, the rail element  612  increases an amount of surface area that can be used to join the enclosure  110  to the support plate  520 , thereby increasing the stiffness of the support plate  520 . In some examples, the enclosure  110  is formed of aluminum and the external surface of the support plate  520  includes a cladded stainless steel layer—e.g., the upper stiffening layer  522 -A. By overlaying the rail element  612  over the external surface of the support plate  520 , there is more surface area to weld between cladded stainless steel and the aluminum. 
       FIGS. 7A-7F  illustrate cross-sectional views of various embodiments of a support plate  700  that is capable of supporting at least one operational component(s) within a cavity of a portable electronic device—e.g., the portable electronic device  100 . 
       FIG. 7A  illustrates a support plate  700 -A, in accordance with some embodiments, where the support plate  700 -A includes a thermally conductive core  724  that is separated by an upper stiffening layer  722 -A having a thickness (T 1 ) and a lower stiffening layer  722 -B having a thickness (T 2 ). As illustrated in  FIG. 7A , the upper and lower stiffening layers  722 -A, B have different thicknesses, where T 2 &gt;T 1 . For example, the upper and lower stiffening layers  722 -A, B may have different stiffening materials; therefore, the support plate  700 -A may be capable of sufficiently supporting the operational component(s). 
       FIG. 7B  illustrates a support plate  700 -B, in accordance with some embodiments, where the support plate  700 -B includes a thermally conductive core  724  that is separated by a left adjacent stiffening layer  722 -A having a width (W 1 ) and a right adjacent stiffening layer  722 -B having a width (W 2 ). It should be noted that the left and right adjacent stiffening layers  722 -A, B may be formed of material that is capable of being welded to the enclosure—e.g., the enclosure  110 —so as to securely fix the support plate  700 -B. According to some examples, the widths W 1 , W 2  of the left and right adjacent stiffening layers  722 -A, B overlap with a sufficient amount of a surface area of the enclosure  110 . In some examples, the widths W 1 , W 2  are different, and in other examples, the widths W 1 , W 2  are the same. 
       FIG. 7C  illustrates a support plate  700 -C, in accordance with some embodiments, where the support plate  700 -C includes multiple thermally conductive cores  724 -A, B that are separated by a left adjacent stiffening layer  722 -A, an intermediate stiffening layer  722 -B, and a right adjacent stiffening layer  722 -B. It should be noted that the left, intermediate, and right stiffening layers  722 -A, B, C are formed of material that is capable of being welded to the enclosure—e.g., the enclosure  110 —so as to securely fix the support plate  700 -C. 
       FIG. 7D  illustrates a support plate  700 -D, in accordance with some embodiments, where a thermally conductive core  724  is formed by removing material from a lower surface of a stiffening layer  722 . 
       FIG. 7E  illustrates a support plate  700 -E, in accordance with some embodiments, where a thermally conductive core  724  is positioned between upper and lower stiffening layers  722 -A, B. In contrast to the support plate  700 -A, the upper stiffening layer  722 -A of the support plate  700 -E has a non-linear geometry that is capable of accommodating for operational component(s) having different geometries and/or support structures (e.g., enclosure  110 , etc.) having different geometries. In some examples, the upper stiffening layer  722 -A may have a generally curved shape, polygonal shape, and the like. Additionally, the lower stiffening layer  722 -B may also have a generally curved shape, polygonal shape, and the like. Beneficially, by adopting an irregular and/or non-linear geometry, the support plate  700 -E is capable of fitting within a cavity and accommodating for different geometries of adjacent support structures (e.g., trim structure, enclosure, etc.) while still being capable of conducting thermal energy and providing a sufficient amount of stiffness. In other words, the geometry of the support plate  700 -E may be modified to adapt to the dimensions of support structures in the portable electronic device—e.g., the portable electronic device  100 . 
       FIG. 7F  illustrates a support plate  700 -F, in accordance with some embodiments, where an end surface of a thermally conductive core  724  is cladded to a stiffening layer  722  along a heat affected zone. Instead of another stiffening layer that is cladded to another end surface of the thermally conductive core  724 , a stiffening element  712  is welded to a lower surface of the enclosure—e.g., the enclosure  110 —and an upper surface of the thermally conductive core  724 . According to some examples, the stiffening element  712  and the support plate  700 -F are supported by the back wall—e.g., the back wall  130 . In some examples, the stiffening element  712  is a unibody construction. 
     With reference to the support plates  700 -A, B, C, D, E, F, it should be noted that these support plates may include different sections having different combinations of layers, dimensions, and/or ratios of materials. For instance, if a greater amount of stiffness is required for the left adjacent stiffening layer  722 -A to weld to the enclosure  110 , then a greater amount of a stiffness-promoting material, such as stainless steel or titanium may be included in the left adjacent stiffening layer  722 -A relative to the right adjacent stiffening layer  722 -B. In another example, with reference to the support plate  700 -C, the thermally conductive core  724 -A may include a greater amount/concentration of a thermally conductive material (e.g., copper, etc.) than the thermally conductive core  724 -B because the thermally conductive core  724 -A supports an operational component (e.g., a battery) that generates a greater amount of heat than the operational component (e.g., a camera) that is supported by the thermally conductive core  724 -B. In some embodiments, a single thermally conductive core—e.g., the thermally conductive core  724  and/or a single stiffening layer—e.g., the upper stiffening layer  722 -A may include different regions having different thicknesses, ratio of materials, and the like in order to impart localized differences in thermal conductivity or stiffness. 
       FIGS. 8A-8B  illustrate different views of a portable electronic device  800  that includes a support plate  830  for supporting at least one operational component, in accordance with some embodiments.  FIG. 8A  illustrates a perspective view and  FIG. 8B  illustrates a cross-sectional view of the portable electronic device  800  that includes a support plate  830  that is welded to the side wall  112 -C. The support plate  830  is welded to the side wall  112 -C as indicated by a weld line  846 . Additionally, the support plate  830  is further joined to the side wall  112 -C using a rail feature  840  for added stiffness. The rail feature  840  includes a fastener  842  that extends through the side wall  112 -C and attaches the rail feature  840  to the side wall  112 -C. The rail feature  840  may also be secured to the side wall  112 -C with weld spots  844 . 
       FIG. 9  illustrates a perspective view of a portable electronic device  900  that includes a support plate  930  for supporting at least one operational component, in accordance with some embodiments. The portable electronic device  900  includes a support plate  930  that is welded to the side wall  112 -C. The support plate  930  is welded to the side wall  112 -C as indicated by a weld line  846 . Additionally, the support plate  930  is further joined to the side wall  112 -C using a rail feature  940  having a dovetail joint  948  that interlocks with the support plate  930 . The support plate  930  is welded to the side wall  112 -C as indicated by a weld line  946 . Additionally, the rail feature  940  includes a fastener  942  that extends through the side wall  112 -C and attaches the rail feature  940  to the side wall  112 -C. The rail feature  940  may also be secured to the side wall  112 -C with weld spots  944 . 
       FIG. 10  illustrates a flow diagram of a method  1000  for forming an enclosure for a portable electronic device that includes a support plate, in accordance with some embodiments. As illustrated in  FIG. 10 , the method  1000  begins at step  1002  where a support plate—e.g., the support plate  520 —is formed by joining a thermally conductive core—e.g., the thermally conductive core  524 —to at least one stiffening layer—e.g., the upper stiffening layer  522 -A. Although the method  1000  is described with reference to the portable electronic device  500  of  FIG. 5 , it should be noted that the method can equally apply to any one of the portable electronic devices  100 ,  200 ,  300 ,  400 ,  500 ,  600 ,  800  or  900  as described herein. 
     At step  1004 , the support plate  520  is joined to metal bands—e.g., the side walls  112 -C of the enclosure  110 . 
     At step  1006 , one or more operational components are secured to a surface of the support plate  520 . 
       FIG. 11  illustrates a system diagram of a portable electronic device  1100  that is capable of implementing the various techniques described herein, according to some embodiments. In particular, the detailed view illustrates various components that can be included in the portable electronic device  100  as illustrated in  FIG. 1 . 
     As shown in  FIG. 11 , the portable electronic device  1100  can include a processor  1110  for controlling the overall operation of the portable electronic device  1100 . The portable electronic device  1100  can include a display  1190 . The display  1190  can be a touch screen panel that can include a sensor (e.g., capacitance sensor). The display  1190  can be controlled by the processor  1110  to display information to the user. A data bus  1102  can facilitate data transfer between at least one memory  1120  and the processor  1110 . The portable electronic device  1100  can also include a network/bus interface  1104  that couples a wireless antenna  1160  to the processor  1110 . 
     The portable electronic device  1100  can include a user input device  1180 , such as a switch. The portable electronic device  1100  includes a power supply unit  1150 , such as a lithium-ion battery. The portable electronic device  1100  also includes a memory  1120 , which can comprise a single disk or multiple disks (e.g., hard drives), and includes a storage management module that manages one or more partitions within the memory  1120 . In some embodiments, the memory  1120  can include flash memory, semiconductor (solid state) memory or the like. The portable electronic device  1100  can also include a Random Access Memory (RAM) and a Read-Only Memory (ROM). The ROM can store programs, utilities or processes to be executed in a non-volatile manner. The RAM can provide volatile data storage, and stores instructions related to the operation of the portable electronic device  1100 . 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20180910
Publication Date: 20200929
Grant Date: 20200929
Priority Date: 20170911
Inventors: HOOTON, LEE E.
RAMMAH, MARWAN
BERTIN, JAMES A.
HRISTOV, STOYAN P.
COUNTS, WILLIAM A.
Assignee: APPLE INC
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Family ID: 65630378