PATENT DOCUMENT

Publication Number: US-8879266-B2
Application Number: US-201213480458-A
Country: US
Kind Code: B2

Title: Thin multi-layered structures providing rigidity and conductivity

Abstract:
Electronic devices having a multi-layer structure that provides enhanced conductivity (thermal and/or electrical conductivity) are disclosed. The multi-layer structure can have a plurality of adjacent layers. At least one layer can primarily provide structural rigidity, and at least another layer can primarily provide enhanced conductivity. The layer of high conductivity can serve to provide the electronic device with greater ability to disperse generated heat and/or to provide an accessible voltage potential (e.g., ground plane). Advantageously, the multi-layer structure can provide enhanced conductivity using an otherwise required structural component and without necessitating an increase in thickness.

Claims:
What is claimed is: 
     
       1. A portable electronic device, comprising:
 an outer housing; 
 an internal support structure provided within the outer housing, the internal support structure being a multi-layered structure having at least (i) a first layer formed of a first material that primarily provides rigidity to the multi-layered structure, and (ii) a second layer formed of a second material that provides for enhanced conductivity as compared to conductivity of the first material, the second material being different than the first material; and 
 at least one electrical component provided within the outer housing, the at least one electrical component being thermally and/or electrically coupled to the second layer of the internal support structure, 
 wherein the first material comprises metal, and the second material comprises metal, 
 wherein the second layer has greater conductivity than the first layer, and wherein the first layer has greater rigidity than the second layer, and 
 wherein the first layer of the multi-layer structure has at least one opening proximate to the at least one electrical component provided within the housing, the at least one opening exposing the second layer of the multi-layer structure. 
 
     
     
       2. A portable electronic device as recited in  claim 1 , wherein the electrical component comprises an integrated circuit chip. 
     
     
       3. A portable electronic device as recited in  claim 1 , wherein the electrical component is mounted on a circuit board. 
     
     
       4. A portable electronic device as recited in  claim 1 , wherein the electrical component comprises an integrated circuit chip, and wherein the integrated circuit chip is thermally and/or electrically coupled to the second layer of the internal support structure via the at least one opening. 
     
     
       5. A portable electronic device as recited in  claim 1 , wherein the at least one electrical component is provided adjacent the first layer of the multi-layered structure. 
     
     
       6. A portable electronic device as recited in  claim 1 , wherein the thickness of the internal support structure is less than about 1 mm. 
     
     
       7. A portable electronic device as recited in  claim 1 , wherein at least one portion of the second layer at the multi-layer structure that is exposed by the at least one opening through the first layer of the multi-layered structure has a coating. 
     
     
       8. A portable electronic device as recited in  claim 7 , wherein the second layer is coated or plated with an anti-corrosive material. 
     
     
       9. A portable electronic device as recited in  claim 6 , wherein the at least one electrical component is thermally and/or electrically coupled to the second layer of the internal support structure via the at least one opening. 
     
     
       10. A portable electronic device as recited in  claim 1 , wherein the multi-layered structure is a multi-layered clad metal structure. 
     
     
       11. A portable electronic device as recited in  claim 1 , where the thickness of the internal support structure is less than about 1 mm. 
     
     
       12. A portable electronic device as recited in  claim 1 , wherein the second material comprises steel, and the second layer comprises copper, aluminum, silver or gold. 
     
     
       13. A portable electronic device as recited in  claim 1 , wherein the internal support structure comprises an internal chassis. 
     
     
       14. A portable electronic device as recited in  claim 1 , wherein the internal support structure comprises a frame. 
     
     
       15. A method for assembly of a portable electronic device, the method comprising:
 providing a multi-layer metal structure to provide support for internal components of the portable electronic device, the multi-layer metal structure including at least one structural layer and at least one highly conductive layer; 
 providing heat-generating electrical components of the portable electronic device that cooperate to support functions of the portable electronic device; and 
 coupling at least one of the heat generating electrical components to the at least one highly conductive layer of the multi-layered structure. 
 
     
     
       16. A method as recited in  claim 15 , wherein the coupling comprises electrical coupling. 
     
     
       17. A method as recited in  claim 15 , wherein the coupling comprises thermally coupling. 
     
     
       18. A method as recited in  claim 15 , wherein the coupling comprises at least one of:
 thermally coupling at least one of the heat generating electrical components to the at least one highly conductive layer; and 
 electrically coupling at least one of the heat generating electrical components to the at least one highly conductive layer. 
 
     
     
       19. A method as recited in  claim 15 ,
 wherein the highly conductive layer serves as a ground plane for the portable electronic device, and 
 wherein the coupling comprises:
 electrically coupling at least one of the heat generating electrical components to the at least one highly conductive layer and thus the ground plane. 
 
 
     
     
       20. A method as recited in  claim 15 , wherein the coupling at least one of the heat generating electrical components to the at least one highly conductive layer of the multi-layered structure comprises:
 forming at least one opening in the at least one structural layer; and 
 coupling at least one of the heat generating electrical components to the at least one highly conductive layer of the multi-layered structure via the at least one opening. 
 
     
     
       21. A method as recited in  claim 20 , wherein the least one of the heat generating electrical components is positioned within the portable electronic device adjacent to the multi-layered structure. 
     
     
       22. A method as recited in  claim 21 , wherein the coupling comprises electrical coupling. 
     
     
       23. A method as recited in  claim 21 , wherein the coupling comprises thermally coupling. 
     
     
       24. A method for assembly of a portable electronic device, the method comprising:
 providing a multi-layered metal structure to provide support for internal components of the portable electronic device, the multi-layer metal structure including at least a first metal layer and at least a second metal layer, the first metal layer having at least one opening that exposes the second metal layer; 
 providing heat-generating electrical components that cooperate to support functions of the portable electronic device; 
 securing at least one of the heat-generating electrical components internal to the portable electronic device and adjacent the at least one opening in the first metal layer of the multi-layer metal structure; and 
 thermally and/or electrically coupling the at least one of the secured heat generating electrical components to the second metal layer of the multi-layered structure via the at least one opening in the first metal layer. 
 
     
     
       25. A method as recited in  claim 24 , wherein the providing of the multi-layer structure comprises:
 obtaining the multi-layer structure without any openings; and 
 forming at least one opening in the first metal layer of the multi-layer structure. 
 
     
     
       26. A method as recited in  claim 24 , wherein the forming of the at least one opening comprises:
 etching at least one opening in the first metal layer of the multi-layer structure. 
 
     
     
       27. A method as recited in  claim 24 ,
 disposing a compliant layer of material between the at least one of the secured heat generating electrical components and the second metal layer of the multi-layered structure via the at least one opening in the first metal layer, so as to facilitate thermal coupling. 
 
     
     
       28. A method as recited in  claim 24 ,
 connecting a conductive member between the at least one of the secured heat generating electrical components and the second metal layer of the multi-layered structure via the at least one opening in the first metal layer, so as to facilitate electrical coupling therebetween. 
 
     
     
       29. A method as recited in  claim 24 , wherein the first metal layer comprises steel, and wherein the second metal layer comprises aluminum or copper. 
     
     
       30. A method as recited in  claim 24 , wherein the multi-layered metal structure further include a third metal layer, and wherein the second metal layer is sandwiched between the first and third metal layers of the multi-layered structure. 
     
     
       31. A method as recited in  claim 24 , wherein the second metal layer has greater conductivity than the first metal layer, and wherein the first metal layer has greater rigidity than the second metal layer. 
     
     
       32. A method as recited in  claim 24 , wherein the first metal layer is a rigid structural layer and the second metal layer is a highly conductive layer.

Description:
BACKGROUND OF THE INVENTION 
     Electronic devices, such as computers, televisions, media players, etc., all include electronic components that generate heat. The heat can be dissipated by heat sinks, fans, etc. In the case of compact portable electronic devices, the limited area and density of electronic components can made heat dissipation more difficult. Since some electronic components produce more heat than others, there is a need to distribute heat in the compact portable electronic device. Also, there can also be a need for improved electrical connection with a ground plane internal to the compact portable electronic device. Hence, there are continuing needs to provide improved ways to dissipate and distribute heat and/or enhance electrical connection in an electronic device, particularly a compact portable electronic device. 
     SUMMARY 
     Embodiments of the invention pertain to electronic devices having a multi-layer structure that provides enhanced conductivity, namely, for improved thermal and/or electrical conductivity. The multi-layer structure can have a plurality of adjacent layers. At least one layer can primarily provide structural rigidity, and at least another layer can primarily provide enhanced conductivity (thermal and/or electrical). The layer of high conductivity can serve to provide the electronic device with greater ability to disperse generated heat and/or to provide an accessible voltage potential (e.g., ground plane). The adjacent layers can be compressed together in a cladding process to yield an integral metal structure. Alternatively, the adjacent layers can be secured together by other means, such as bonding. 
     Given that multi-layer structure has a plurality of adjacent layers for thermal and/or electrical conductivity, electronic components that are generating heat or requiring electrical grounding need access to the layer with high conductivity. Depending on the orientation and/or configuration of the multi-layer structure, one or more openings can be provided in the layer providing structural rigidity so that access to the layer providing the high conductivity can be had via the one or more openings in the layer providing structural rigidity. 
     Advantageously, the multi-layer structure can provide enhanced conductivity using an otherwise required structural component and without necessitating an increase in thickness. Consequently, the enhanced conductivity can be provided without significantly sacrificing structural support. Hence, the multi-layer structure is well suited for compact portable electronic devices where thin and compact components are a necessity. 
     The invention can be implemented in numerous ways, including as a method, system, device, or apparatus. Several embodiments of the invention are discussed below. 
     As a portable electronic device, one embodiment can, for example, include at least an outer housing, an internal support structure provided within the outer housing, and at least one electrical component provided within the outer housing. The internal support structure is a multi-layered structure having at least (i) a first layer form of a first material that primarily provides rigidity to the multi-layered structure, and (ii) a second layer formed of a second material that provides for enhanced conductivity as compared to conductivity of the first material. The second material is different than the first material. The at least one electrical component being thermally and/or electrically coupled to the second layer of the internal support structure. 
     As a method for assembly of a portable electronic device, one embodiment can, for example, include at least: providing a multi-layer metal structure to provide support for internal components of the portable electronic device, the multi-layer metal structure including at least one structural layer and at least one highly conductive layer; providing heat-generating electrical components of the portable electronic device that cooperate to support functions of the portable electronic device; and coupling at least one of the heat generating electrical components to the at least one highly conductive layer of the multi-layered structure. 
     As a method for assembly of a portable electronic device, one embodiment can, for example, include at least: providing a multi-layered metal structure to provide support for internal components of the portable electronic device, the multi-layer metal structure including at least a first metal layer and at least a second metal layer, the first metal layer having at least one opening that exposes the second metal layer; providing heat-generating electrical components that cooperate to support functions of the portable electronic device; securing at least one of the heat-generating electrical components internal to the portable electronic device and adjacent the at least one opening in the first metal layer of the multi-layer metal structure; and thermally and/or electrically coupling the at least one of the secured heat generating electrical components to the second metal layer of the multi-layered structure via the at least one opening in the first metal layer. 
     Other aspects and advantages of embodiments of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  is a flow diagram of a conductivity coupling process according to one embodiment. 
         FIG. 2A  illustrates a cross-sectional view of a multi-layer metal structure according to one embodiment. 
         FIG. 2B  illustrates a cross-sectional view of a multi-layer metal structure according to another embodiment. 
         FIG. 2C  illustrates a cross-sectional view of a multi-layer metal structure according to another embodiment. 
         FIG. 3A  illustrates a cross-sectional view of a conductivity assembly according to one embodiment. 
         FIG. 3B  illustrates a cross-sectional view of a conductivity assembly according to another embodiment. 
         FIG. 3C  illustrates a cross-sectional view of a conductivity assembly according to another embodiment. 
         FIG. 3D  illustrates a cross-sectional view of a conductivity assembly according to another embodiment. 
         FIG. 4  is a flow diagram of a conductivity coupling process according to one embodiment. 
         FIG. 5  illustrates a flow diagram of a conductivity coupling process according to another embodiment. 
         FIG. 6  is a cross-sectional view of a portable electronic device according to one embodiment. 
         FIGS. 7A-7D  illustrates assembly of internal portions of a portable electronic device according to one embodiment. 
         FIG. 8  is a cross-sectional view of a portable electronic device according to another embodiment. 
         FIG. 9  is a cross-sectional view of a portable electronic device according to another embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     Embodiments of the invention pertain to electronic devices having a multi-layer structure that provides enhanced conductivity, namely, for improved thermal and/or electrical conductivity. The multi-layer structure can have a plurality of adjacent layers. At least one layer can primarily provide structural rigidity, and at least another layer can primarily provide enhanced conductivity (thermal and/or electrical). The layer of high conductivity can serve to provide the electronic device with greater ability to disperse generated heat and/or to provide an accessible voltage potential (e.g., ground plane). The adjacent layers can be compressed together in a cladding process to yield an integral metal structure. Alternatively, the adjacent layers can be secured together by other means, such as bonding. 
     Given that multi-layer structure has a plurality of adjacent layers for thermal and/or electrical conductivity, electronic components that are generating heat or requiring electrical grounding need access to the layer with high conductivity. Depending on the orientation and/or configuration of the multi-layer structure, one or more openings can be provided in the layer providing structural rigidity so that access to the layer providing the high conductivity can be had via the one or more openings in the layer providing structural rigidity. 
     Advantageously, the multi-layer structure can provide enhanced conductivity using an otherwise required structural component and without necessitating an increase in thickness. Consequently, the enhanced conductivity can be provided without significantly sacrificing structural support. Hence, the multi-layer structure is well suited for compact portable electronic devices where thin and compact components are a necessity. 
     Embodiments of the invention are discussed below with reference to  FIGS. 1-9 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. The illustrations provided in these figures are not necessarily drawn to scale; instead, the illustrations are presented in a manner to facilitate presentation. 
       FIG. 1  is a flow diagram of a conductivity coupling process  100  according to one embodiment. The conductivity coupling process  100  can operate to provide enhanced thermal and/or electrical coupling for electrical components utilized within a housing of an electronic device. The conductivity coupling provided allows for thermal and/or electrical coupling with efficient use of space, thus making it well suited for use within portable electronic devices. 
     The conductivity coupling process  100  can initially provide  102  a multi-layer metal structure having at least a structural layer and a highly conductive layer. The multi-layer metal structure can be associated with a support structure of an electronic device, such as a portable electronic device. The support structure can be internal to a housing of the electronic device, or can be part of the housing of the electronic device. In addition, one or more heat-generating electrical components can be provided  104 . The one or more heat-generating electrical components can, for example, be electronic devices, such as packaged integrated circuits. The one or more heat-generating electrical components can then be coupled  106  to the highly conductive layer of the multi-layer metal structure. As a result, even though the multi-layer metal structure has a plurality of different layers, with some layers offering more structural support and other layers offering greater conductivity, a heat generating electrical component can be coupled to a highly conductive layer so as to facilitate thermal and/or electrical conductivity. 
     The multi-layer metal structure includes two or more layers. Typically, the two or more layers are metal layers. In one embodiment, at least one of the layers of the multi-layer metal structure is a layer that offers high conductivity. Typically, the conductivity for this metal layer would be high or enhanced for one or both of thermal and electrical conductivity. As an example, the layer that offers high conductivity can be formed from one or more of copper, aluminum, silver or gold. The other of the layers of the multi-layer metal structure typically primarily provide structural support. As an example, the other of all the layers that primarily provide structural support can be formed from steel, such as stainless steel. 
     The multi-layer metal structure can also be formed such that the individual layers are essentially integral with one another or otherwise, bonded together. As an example, the multi-layer metal structure can be a clad metal structure in which cladding is used to bind the multiple layers together. In one embodiment, the multi-layer metal structure is a thin multi-layered structure, which can have a thickness that is less than about 1 mm. In another embodiment, the multi-layer metal structure is a thin multi-layered structure, which can have a thickness that is less than about 0.5 mm. In still another embodiment, the multi-layer metal structure is a thin multi-layered structure, which can have a thickness that is about 0.3 mm. Although the multi-layer structure is generally thin, the thickness is dependent upon the number of layers utilized and the thickness of the individual layers. For example, with a thin multi-layered structure, the thickness of a given layer can be on the order of 0.05 mm to 0.5 mm 
       FIG. 2A  illustrates a cross-sectional view of a multi-layer metal structure  200  according to one embodiment. The multiple-layer metal structure  200  is a multi-layer structure formed from a first layer  202  and a second layer  204 . In this embodiment, the first layer  202  can primarily provide structural support, while the second layer  204  can primarily provide enhanced conductivity. 
       FIG. 2B  illustrates a cross-sectional view of a multi-layer metal structure  220  according to another embodiment. The multiple-layer metal structure  220  is a multi-layer structure formed from a first layer  222 , a second layer  224 , and a third layer  226 . In this embodiment, the first layer  222  and the third layer  226  can primarily provide structural support, while the second layer  224  can primarily provide enhanced conductivity. For example, in thin applications, the thickness of each of the layers  222 ,  224  and  226  can be about 0.1 mm to 0.3 mm; hence, the overall thickness of the multiple-layer metal structure  220  can be on the order of about 0.3 mm to 0.9 mm. While the overall thickness of the multiple-layer metal structure  220  remains thin, the use of the second layer  224  (which is distinct from the first layer  222  and the third layer  226 ) operates to provide a high conductivity internal layer that is sandwiched by other layers that provide structural rigidity to the multi-layer metal structure  220 . The overall strength of the multi-layer metal structure  220  can be rendered similar to that offered by a uniform single layer metal structure of the structural rigidity material which has the same thickness. 
       FIG. 2C  illustrates a cross-sectional view of a multi-layer metal structure  240  according to another embodiment. The multiple-layer metal structure  240  is a multi-layer structure formed from a first layer  242 , a second layer  244 , and a third layer  246 . In this embodiment, the first layer  242  and the third layer  246  can primarily provide structural support, while the second layer  244  can primarily provide enhanced conductivity. In general, the multiple-layer metal structure  240  illustrated in  FIG. 2C  is generally similar to the multiple-layer metal structure  220  illustrated in  FIG. 2B . The difference, however, is that the second layer  244  in  FIG. 2C  has a greater thickness than the second layer  224  illustrated in  FIG. 2B . The greater the thickness of the second layer  244 , the greater the thermal mass available to absorb heat. Hence, the multi-layer metal structure  240  illustrated in  FIG. 2C  can offer greater thermal conductivity and heat absorption than does the multi-layer metal structure  220 . Hence, if the primarily conductive layer of a multi-layer metal structure is to be utilized for thermal conductivity, the thickness, and thus the mass (or volume), of the primarily conductive layer can be configured as appropriate for the desired application. 
       FIG. 3A  illustrates a cross-sectional view of a conductivity assembly  300  according to one embodiment. The conductivity assembly  300  includes a multi-layer metal structure  302 . The multi-layer metal structure  302  includes a support layer  304  and a conductivity layer  306 . The support layer  304  primarily provides structural rigidity to the multi-layer metal structure  302 , and the conductivity layer  306  provides high conductivity (e.g., thermal and/or electrical) to the multi-layer metal structure  302 . The conductivity assembly  300  also includes one or more heat-generating electrical components  310 . In the event that the heat-generating electrical components  310  are placed adjacent the support layer  304  of the multi-layer metal structure  302 , one or more openings  308  can be provided through the support layer  304 . As a result, the one or more heat-generating electrical components  310  can gain access to the conductivity layer  306  via the one or more openings  308 . In one implementation, as illustrated in  FIG. 3A , the one or more heat-generating electrical components  310  can be placed over a corresponding one or more of the openings  308 . In addition, a compliant conductive material  310  can be placed in the one or more openings  308  between the one or more heat-generating electrical components  310  and the conductivity layer  306  so as to provide conductive coupling therebetween. As a result, the one or more heat-generating electrical components  310  can be coupled to the conductivity layer  306 . Typically, in such an embodiment, the conductivity layer  306  is provided for thermal conductivity and thus the compliant conductive material  312  can facilitate thermal coupling between the heat-generating electrical component  310  and the conductivity layer  306 . The compliant conductive material  310  can vary depending upon implementation, but could include silicone with conductive elements (e.g., graphite), thermally conductive adhesive, silver paste, etc. 
       FIG. 3B  illustrates a cross-sectional view of a conductivity assembly  320  according to another embodiment. The conductivity assembly  320  is generally similar to the conductivity assembly  300  illustrated in  FIG. 3A . However, the primary distinction between the two embodiments is that the conductivity assembly  320  utilizes a multi-layer metal structure  322  that consist of three layers, whereas the conductivity assembly  300  illustrated in  FIG. 3A  utilizes a multi-layer metal structure  302  that consist of two layers. 
     The conductivity assembly  320  includes a multi-layer metal structure  322 . The multi-layer metal structure  322  includes a support layer  324 , a conductivity layer  326  and another support layer  328 . The support layers  324  and  328  primarily provides structural rigidity to the multi-layer metal structure  322 , and the conductivity layer  326  provides high conductivity (e.g., thermal and/or electrical) to the multi-layer metal structure  322 . The conductivity layer  326  is provided in between the first support layer  324  and the second support layer  328 . In other words, the conductivity layer  326  is sandwiched in between the first support layer  324  and the second support layer  328 . The multi-layer structure  322  can have the different layers integrally formed, such as through cladding. 
     The conductivity assembly  320  also includes one or more heat-generating electrical components  330 . In the event that the heat-generating electrical components  330  are placed adjacent the support layer  324  of the multi-layer metal structure  322 , one or more openings  332  can be provided through the support layer  324 . As a result, the one or more heat-generating electrical components  330  can gain access to the conductivity layer  326  via the one or more openings  332 . In one implementation, as illustrated in  FIG. 3B , the one or more heat-generating electrical components  330  can be placed over a corresponding one or more of the openings  332 . In addition, a compliant conductive material  334  can be placed in the one or more openings  332  between the one or more heat-generating electrical components  330  and the conductivity layer  326  so as to provide conductive coupling therebetween. As a result, the one or more heat-generating electrical components  330  can be coupled to the conductivity layer  326 . Typically, in such an embodiment, the conductivity layer  326  is provided for thermal conductivity and thus the compliant conductive material  334  can facilitate thermal coupling between the heat-generating electrical component  330  and the conductivity layer  326 . The compliant conductive material  334  can vary depending upon implementation, but could include silicone with conductive elements (e.g., graphite), thermally conductive adhesive, silver paste, etc. 
       FIG. 3C  illustrates a cross-sectional view of a conductivity assembly  340  according to another embodiment. The conductivity assembly  340  includes a multi-layer metal structure  342 . The multi-layer metal structure  342  includes a support layer  344  and a conductivity layer  346 . The support layer  344  primarily provides structural rigidity to the multi-layer metal structure  342 , and the conductivity layer  346  provides high conductivity to the multi-layer metal structure  342 . The support layer  344  can have at least one opening  348  to provide access to the conductivity layer  346  through the support layer  344 . The conductivity assembly  340  can also include at least one electronic component  350 , which is often a heat-generating electrical component. As an example, the electronic component  350  can pertain to an electronic circuit, such as an integrated circuit device (typically provided in an integrated circuit package). The electronic component  350  is able to be electrically connected to the conductivity layer  346  with a conductor  352 . The conductor  352  can, for example, be implemented by a wire. In other words, through the opening  348  in the support layer  344 , the conductor  352  is able to be electrically connected between the electronic component  350  and the conductivity layer  346 . As a result, the conductor  352  can serve to electrically couple the electronic component  352  to the conductivity layer  346 . In one implementation, the conductivity layer  346  can provide a ground plane (or other voltage potential) for use by an electronic apparatus that includes the conductivity assembly  340 . Advantageously, for electrical coupling, the conductivity layer  346  offers low surface (or contact) resistance. Typically, the electronic component  350 , as well as the conductivity assembly  340 , would be provided internal to a housing for an electronic apparatus (e.g., portable electronic device). Additionally, within the housing for the electronic apparatus, an electronic substrate  354  can be provided. For example, the electronic substrate  354  can pertain to a printed circuit board or a flexible circuit board. The electronic component  350  can be mounted on and secured to the electronic substrate  354 . Hence, in this embodiment, the conductivity layer  346  is electrically coupled to the electronic component  350  by the conductor  352 . 
       FIG. 3D  illustrates a cross-sectional view of a conductivity assembly  360  according to another embodiment. The conductivity assembly  360  includes a multi-layer metal structure  362 . The multi-layer metal structure  362  includes a first support layer  364 , a conductivity layer  366  and a second support layer  368 . The conductivity layer  366  is provided in between the first support layer  364  and the second support layer  368 . In other, the conductivity layer  366  is sandwiched in between the first support layer  364  and the second support layer  368 . The multi-layer structure  362  can have the different layers integrally formed, such as through cladding. 
     To gain access to the conductivity layer  366 , a first opening  370  and a second opening  372  can be provided in the first support layer  364 . The first opening  370  is configured to facilitate thermal coupling with a heat-generating electrical component  374 . For example, the electrical component  374  can be provided over the opening  370  and adjacent to the support layer  364 . A compliant conductive material  380  can be deposited in the opening  370  and between the heat-generating electrical component  374  and the conductivity layer  366 . In addition, an electrical component  376  can be provided over the opening  372  and adjacent to the support layer  364 . The second opening  372  is configured to facilitate electrical coupling with an electronic device  376 . A conductive member  382  can be placed in the opening  374  to electrically connect the electronic device  376  to the conductivity layer  366 . Additionally, within the housing for the electronic apparatus, an electronic substrate  378  can be provided. For example, the electronic substrate  378  can pertain to a printed circuit board or a flexible circuit board. The heat-generating electrical component  374  and the electronic component  376  can both be mounted on and secured to the electronic substrate  378 . Hence, in this embodiment, the conductivity layer  366  is thermally coupled to the heat-generating electrical component  374  and also electrically coupled to the electronic component  376 . 
     In this embodiment, the conductivity layer  366  is thermally coupled to the heat-generating electrical component  374  and is electrically coupled to the electronic component  376 . Hence, in this embodiment, the conductivity layer  366  serves to provide both thermal and electrical conductivity. For example, the thermal conductivity can provide heat dispersion and/or removal as well as electrical coupling (such as for grounding or other voltage potential). 
       FIG. 4  is a flow diagram of a conductivity coupling process  400  according to one embodiment. The conductivity coupling process  400  can operate to provide enhanced thermal and/or electrical coupling for electrical components utilized within a housing of an electronic device. The conductivity coupling provided allows for thermal and/or electrical coupling with efficient use of space, thus making it well suited for use within portable electronic devices. 
     The conductivity coupling process  40  can provide  402  a multi-layered metal structure having a first metal layer and a second metal layer. The first metal layer can have at least one opening that exposes a second metal layer. A heat-generating electrical component can also be provided  404 . Thereafter, the heat-generating electrical component can be secured  406  internal to the portable electronic device and adjacent at least one opening in the first metal layer. Also, the heat-generating electrical components can be thermally and/or electrically coupled  408  to the second metal layer via the at least one opening in the first metal layer. In this regard, by coupling  408  the heat-generating electrical component to the second metal layer, the second metal layer, which offers enhanced conductivity (as compared to the first metal layer), provides enhanced thermal and/or electrical coupling with the second metal layer having the enhanced conductivity. Following the coupling  408 , the conductivity coupling process  400  can end. 
       FIG. 5  illustrates a flow diagram of a conductivity coupling process  500  according to another embodiment. The conductivity coupling process  500  operates to provide enhanced thermal and/or electrical coupling for one or more electrical components utilized within a housing of an electronic device. The conductivity coupling provided allows for thermal and/or electrical coupling with efficient use of space, thus making it well suited for use within portable electronic devices. 
     The conductivity coupling process  500  can provide  502  a multi-layered metal structure having a first metal layer, a second metal layer, and a third metal layer. In one implementation, the first and third metal layers are primarily provided for structural support, such as rigidity for the multi-layered metal structure, and the second metal layer is primarily provided for enhanced conductivity. In addition, a heat-generating electrical component can be provided  504 . Further, at least one opening in the first metal layer of the multi-layer structure can be formed  506 . Thereafter, the heat-generating electrical component can be secured  508  internal to the electronic device and adjacent the at least one opening in the first metal layer. Next, the heat-generating electrical component can be thermally and/or electrically coupled  510  to the second metal layer via at least one opening in the first metal layer. Following the coupling  510 , the conductivity coupling process  500  can end. 
       FIG. 6  is a cross-sectional view of a portable electronic device  600  according to one embodiment. The portable electronic device  600  includes an outer housing that has a front housing portion  602 , a back housing portion  604 , a side housing portion  606  and a side housing portion  608 . Internal to the outer housing for the portable electronic device  600  is an interior area  609 . 
     Various structures and electrical components can be provided within the interior area  609  to facilitate operation of the portable electronic device  600 . In this embodiment, included within the internal area  609  is a multi-layer support structure  610 . The multi-layer support structure  610  can, for example, pertain to a frame, tray or internal chassis. The multi-layer support structure  610  can be formed from two or more layers that are integrally bonded together as discussed above. Of the two or more layers, at least one is primarily a support layer and at least one is primarily a conductivity layer. Also included within the internal area  609  is a substrate  612 . The substrate  612  supports electrical interconnections with a plurality of electrical components, including electrical components  614 ,  616 ,  618 ,  620  and  622 . As illustrated in  FIG. 6 , the electrical components  614 ,  616  and  618  are provided on a top side of the substrate  612 , while the electrical components  620  and  622  are provided on a bottom side of the substrate  612 . 
     As arranged within the internal area  609 , the substrate  612  is placed over or adjacent the multi-layer support structure  610 . Additionally, to facilitate conductivity between certain electrical components mounted on the substrate  612 , the multi-layer support structure  610  can include openings  624 ,  626  and  628  that effectively expose the bottom or internal layer (e.g., conductivity layer) which offers enhanced conductivity as compared to the top layer (e.g., support layer). As illustrated in  FIG. 6 , the placement of the openings  624 ,  626  and  628  can correspond to and be positioned adjacent the electrical components mounted on the bottom side of the substrate  612 . 
     In particular, the electrical component  620  can be provided adjacent the opening  624 . Additionally, a compliant material  630 , which is also conductive, can be placed between the electrical component  620  and the opening  624 . Hence, the arrangement of the electrical component  620  and the opening  624  (as well as the placement of the compliant material  630 ) establishes a high conductivity path from the electrical component  620  and the bottom or internal layer (e.g., conductivity layer) of the multi-layer support structure  610 . A conductor  632 , such as a wire) can be coupled between the substrate  612  (or electrical component(s) thereon) to the bottom or internal layer (e.g., conductivity layer) of the multi-layer support structure  610  so as to provide electrical coupling therebetween. The electrical component  622  can be provided adjacent the opening  628 . Additionally, a compliant material  634 , which is also conductive, can be placed between the electrical component  622  and the opening  628 . Hence, the arrangement of the electrical component  622  and the opening  628  (as well as the placement of the compliant material  634 ) establishes a high conductivity path from the electrical component  622  to the bottom or internal layer (e.g., conductivity layer) of the multi-layer support structure  610 . 
     Accordingly, in the embodiment illustrated in  FIG. 6 , the conductor  632  is provided to render an electrical connection between the substrate  612  and the bottom or internal layer of the multi-layer support structure  610 , and the opening  624  and  628  (along with the compliant material  630  and  634 ) are utilized to provide thermal coupling between the electrical components  620  and  622  and the bottom or internal layer of the multi-layer support structure  610  which offers high thermal conductivity. Still further, within the internal area  609 , one or more brackets  636  can be provided to secure the substrate  612  relative to the multi-layer support structure  610 . 
       FIGS. 7A-7D  illustrate assembly of internal portions of a portable electronic device according to one embodiment. 
       FIG. 7A  illustrates a sub-assembly  700  according to one embodiment. The sub-assembly  700  includes a substrate  612  that includes various electrical components  614 - 622  mounted thereon. As illustrated in  FIG. 7A , the electrical components  614 ,  616  and  618  are provided on a top side of the substrate  612 , while the components  620  and  622  are mounted on the bottom side of the substrate  622 . The electrical components  614 - 622  can refer to integrated circuits or other electronic components (e.g., amplifiers, microprocessor, microcontroller, etc.), which are typically provided as packaged products. The sub-assembly  700  can be referred to as a printed circuit board, a flex circuit and the like having electrical components mounted thereto. 
       FIG. 7B  illustrates a multi-layer support structure  720  according to one embodiment. The multi-layer support structure  720  is one implementation of the multi-layer support structure  610  illustrated in  FIG. 6 . In this regard, the multi-layer substrate  720  includes a first layer  722  and a second layer  724 , but as noted above could include additional layers. The first layer can primarily provide structural rigidity, and the second layer can primarily provide high conductivity. Within the first layer  722 , a plurality of openings  624 ,  626  and  628  are formed to facilitate access to the second layer  724 . Namely, at the openings  624 ,  626  and  628 , the corresponding portion of the first layer  722  has been removed. However, the overall percentage of the first layer  722  being removed to support the openings  624 ,  626  and  628  is relatively small so that the strength, i.e. rigidity, of the first layer  722  is not significantly compromised. The multi-layer substrate  720  can also include first and second side portions  732  and  734 , respectively. 
     The openings  624 ,  626  and  628  in the first layer  722  can be formed in a variety of ways. In one embodiment, the openings can be selectively formed using a semiconductor chemical etching process. In another embodiment, the openings can be selectively formed using a mechanical machining process. In still another embodiment, the opening can be selectively formed in the first layer  722  on fabrication, such as by punching through the opening in the first layer  722  before bonding it to the second layer  724 . 
     It should be noted that at the openings  624 ,  626  and  628  the exposed metal associated with the second layer  724  can be susceptible to corrosion. The susceptibility to corrosion is dependent on the particular metal utilized in the second layer  724 . For example, if the metal utilize for the second layer  724  is copper, it can corrode fairly rapidly. The conductivity of the second layer degrades when the interfacing surface of the second layer  724  at the openings  624 ,  626  and  628  has corroded. Hence, an additional coating (not shown) can be provided at least at the opening  624 ,  626  and  628  to prevent corrosion, namely, by sealing at least the exposed portions of the second layer  724 . The coating is typically a relatively conductive material that is substantially less susceptibly to corrosion, such as nickel or gold which are considered anti-corrosive materials. 
       FIG. 7C  illustrates a compact assembly  760  according to one embodiment. The compact assembly  760  pertains to an assembly of the substrate  700  shown in  FIG. 7A  and the multi-layer support structure  720  shown in  FIG. 7B . As assembled, the substrate  700  is provided over and adjacent the first layer  722  of the multi-layer support structure  720 . Additionally, the electrical component  620  is provided over and adjacent the corresponding opening  624  in the first layer  722  of the multi-layer support structure  720 . Similarly, the electrical component  622  is provided over and adjacent the corresponding opening  628  in the first layer  722  of the multi-layer support structure  720 . Additionally, the compliant formal material  630  and  634  can be respectively provided in the openings  624  and  628  so as to facilitate conductive coupling. The bracket  636  can be used to secure the substrate  612  relative to the multi-layer support structure  720 . The bracket  636  can utilize adhesive, rivets, screws, welds, and the like to couple the substrate  612  to the multi-layer support structure  720 . 
       FIG. 7D  illustrates the compact assembly  740  illustrated in  FIG. 7C  provided within an external housing for a portable electronic device according to one embodiment. The compact housing  740  fits within the internal area  609  and can be secured to one or more of the back housing portion  604  and the side housing portions  606  and  608 . Thereafter, the top housing portion  602  can be provided to complete the enclosure of the internal area  609 , and the resulting portable electronic device is as shown in  FIG. 6 . 
       FIG. 8  is a cross-sectional view of a portable electronic device  800  according to another embodiment. In this embodiment, the portable electronic device  800  is generally similar to the portable electronic device  600  illustrated in  FIG. 6  but further includes a touch screen. 
     The portable electronic device  800  includes an outer housing that has a cover glass  802  which serves as a front housing portion. The outer housing also includes the back housing portion  604 , the side housing portion  606  and the side housing portion  608 . A display screen module  804  is provided in the internal area  609  adjacent to the cover glass  802 . A peripheral adhesive layer  806  can be used at least in part to secure the display screen module  804  to the inside surface of the cover glass  802 . Additionally, within the internal area  609 , one or more brackets  808  can be provided to secure the cover glass  802  and/or the display screen module  804 . The brackets  808  can be secured to the side housing portions  606  and  608  by any of a variety of means, and can secure the cover glass  802  thereto with an adhesive layer  810 . 
     Internal to the outer housing for the portable electronic device  600  is the interior area  609 . Various structures and electrical components can be provided within the interior area  609  to facilitate operation of the portable electronic device  800 . In this embodiment, included within the internal area  609  is the multi-layer support structure  720  ( 610 ). The multi-layer support structure  720  can be formed from two or more layers that are integrally bonded together as discussed above. Of the two or more layers, at least one is primarily a support layer and at least one is primarily a conductivity layer. Also included within the internal area  609  is the sub-assembly  700  which includes the substrate  612  and the electrical components. As illustrated in  FIG. 8 , within the internal area  609 , the sub-assembly  700  is placed over or adjacent the multi-layer support structure  720 . Additionally, to facilitate conductivity between certain electrical components mounted on the substrate  612 , the multi-layer support structure  720  can include openings (e.g.,  624 ,  626  and  628 ) that effectively expose the bottom or internal layer (e.g., conductivity layer) which offers enhanced conductivity as compared to the top layer (e.g., support layer). As illustrated in  FIG. 8 , the placement of the opening can correspond to and be positioned adjacent the electrical components mounted on the bottom side of the substrate  612 . 
     Additionally, a compliant material, which is also conductive, can be placed between the electrical components and the openings. Hence, the arrangement of the electrical components and the opening (as well as the placement of the compliant material or conductor) can establish a high conductivity path from the electrical component to the bottom or internal layer (e.g., conductivity layer) of the multi-layer support structure  720 . 
       FIG. 9  is a cross-sectional view of a portable electronic device  900  according to another embodiment. The portable electronic device  900  includes an outer housing that has a front housing portion  902 , a back housing portion  904 , a side housing portion  906  and a side housing portion  908 . 
     Internal to the outer housing for the portable electronic device  900  is an interior area  909 . Various structures and electrical components can be provided within the interior area  909  to facilitate operation of the portable electronic device  900 . In this embodiment, the back housing portion  904  of the outer housing is a multi-layer structure having an internal high conductivity layer  910 . The multi-layer support structure can be formed from three layers that are integrally bonded together. Of the three layers, first and third layers are primarily for support and second layer is primarily for enhanced conductivity (i.e., the internal high conductivity layer  910 ). Also included within the internal area  909  is a substrate  912 . The substrate  912  supports electrical interconnections with a plurality of electrical components, including electrical components  914 ,  916 ,  918 ,  920  and  922 . As illustrated in  FIG. 9 , the electrical components  914 ,  916  and  918  are provided on a top side of the substrate  912 , while the electrical components  920  and  922  are provided on a bottom side of the substrate  912 . 
     As arranged within the internal area  909 , the substrate  912  is placed over or adjacent the multi-layer support structure. Additionally, to facilitate conductivity between certain electrical components mounted on the substrate  912 , the multi-layer support structure can include openings  924 ,  926  and  928  in the first layer (e.g., support layer) that effectively expose the second (internal) layer (e.g., conductivity layer) which offers enhanced conductivity as compared to the first layer. As illustrated in  FIG. 9 , the placement of the openings  924 ,  926  and  928  in the first layer of the multi-layer support structure can correspond to and be positioned adjacent the electrical components mounted on the bottom side of the substrate  912 . 
     In particular, the electrical component  920  can be provided adjacent the opening  924 . Additionally, a compliant material  930 , which is also conductive, can be placed between the electrical component  920  and the opening  924 . Hence, the arrangement of the electrical component  920  and the opening  924  (as well as the placement of the compliant material  930 ) establishes a high conductivity path from the electrical component  920  to the second layer (e.g., conductivity layer) of the multi-layer support structure. A conductor  932 , such as a wire) can be coupled between the substrate  912  (or electrical component(s) thereon) to the second layer (e.g., conductivity layer) of the multi-layer support structure so as to provide electrical coupling therebetween. The electrical component  922  can be provided adjacent the opening  928 . Additionally, a compliant material  934 , which is also typically conductive, can be placed between the electrical component  922  and the opening  928 . Hence, the arrangement of the electrical component  922  and the opening  928  (as well as the placement of the compliant material  934 ) establishes a high conductivity path from the electrical component  922  to the second layer (e.g., conductivity layer) of the multi-layer support structure. 
     Accordingly, in the embodiment illustrated in  FIG. 9 , the conductor  932  is provided to render an electrical connection between the substrate  912  and the second layer of the multi-layer support structure  910 , and the opening  924  and  928  (along with the compliant material  930  and  934 ) are utilized to provide thermal coupling between the electrical components  920  and  922  and the second layer of the multi-layer support structure  910  which offers high thermal conductivity. Still further, within the internal area  909 , one or more brackets  936  can be provided to secure the substrate  912  relative to the multi-layer support structure. 
     Although the embodiments discussed above utilize a multi-layer support structure in which and internal layer provides height conductivity, it should be understood that the multi-layer support structure could utilize multiple distinct layers of conductivity, such as for different voltage potentials. For example, in a five layer support structure, the first and fifth layers could be primarily for support, the third layer could be for support and/or isolation, and the second and fourth layers could be primarily for conductivity. Additionally, the second and fourth players could be electrically isolated, such as by the third layer. 
     Still further, in other embodiments, it should be understood that the high conductivity layer within a multiple-layer support structure could be manufactured to have a pattern, shape, etc. or otherwise not consume an entire layer. For example, in a given height content to the layer, there could be two or more isolated regions of conductivity. For purposes of electrical conductivity, the use of distinct isolated conductivity regions can permit different voltage potentials to reside within a given height conductivity layer. 
     As used herein, an electrical device can pertain to a wide variety of products, including consumer electronic devices. The electronic devices can include televisions, computing devices, including computers (e.g., desktop, notebook, tablet, etc.), mobile telephones, game players, remote controllers, media players and various other devices. 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     Although only a few embodiments of the invention have been described, it should be understood that the invention may be embodied in many other specific forms without departing from the spirit or the scope of the present invention. By way of example, the steps associated with the methods of the invention may vary widely. Steps may be added, removed, altered, combined, and reordered without departing from the spirit of the scope of the invention. Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. 
     While this specification contains many specifics, these should not be construed as limitations on the scope of the disclosure or of what may be claimed, but rather as descriptions of features specific to particular embodiment of the disclosure. Certain features that are described in the context of separate embodiments can also be implemented in combination. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. 
     While this invention has been described in terms of several embodiments, there are alterations, permutations, and equivalents, which fall within the scope of this invention. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention.

Metadata:
Filing Date: 20120524
Publication Date: 20141104
Grant Date: 20141104
Priority Date: 20120524
Inventors: JARVIS DANIEL W.
DINH RICHARD HUNG MINH
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K1/0207", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/0207", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/182", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/0338", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/30", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4913", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/30", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/182", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/0338", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 49621444