PATENT DOCUMENT

Publication Number: US-9072165-B2
Application Number: US-201213527482-A
Country: US
Kind Code: B2

Title: Hollow conductive gaskets with curves and openings

Abstract:
Electronic devices may be provided with conductive structures such as displays and conductive housing walls. Conductive gaskets may be used to form electrical paths between opposing conductive structures in an electronic device. The conductive gaskets may be formed from conductive sheets of material such as conductive fabric sheets. The conductive fabric or other conductive sheets may form conductive gasket wall structures that extend around air-filled cavities in the conductive gaskets. A conductive gasket may have an elongated shape such as a tubular shape that is characterized by a longitudinal axis. The longitudinal axis may follow a straight path or a curved path. To facilitate bending of a hollow conductive gasket to follow a curved path, the wall structures of the gasket may be provided with openings. Cables may be held in place using flaps of gasket wall material and may run through interior portions of a hollow gasket.

Claims:
What is claimed is: 
     
       1. Apparatus, comprising:
 an elongated hollow tubular conductive gasket comprising a gasket wall structure of conductive fabric that extends around a hollow air-filled interior cavity, wherein the conductive fabric comprises woven fibers; 
 at least one cable; and 
 at least one flap of the conductive fabric that covers part of the cable, wherein the at least one flap extends through the hollow air-filled interior cavity from a first side of the elongated hollow tubular conductive gasket to an opposing second side of the elongated hollow tubular conductive gasket. 
 
     
     
       2. The apparatus defined in  claim 1  wherein the gasket wall structure comprises at least one opening. 
     
     
       3. The apparatus defined in  claim 2  wherein the at least one opening comprises a plurality of openings configured to form air passageways through the elongated hollow tubular conductive gasket from one side of the hollow tubular conductive gasket to another. 
     
     
       4. The apparatus defined in  claim 1  wherein the cable comprises a transmission line cable coupled to at least one antenna. 
     
     
       5. The apparatus defined in  claim 1  wherein the conductive fabric includes openings, wherein the elongated hollow tubular conductive gasket is curved to follow a curved path, and wherein the openings are configured to facilitate bending of the elongated hollow tubular conductive gasket without wrinkling. 
     
     
       6. The apparatus defined in  claim 1  further comprising at least one engagement structure attached to the elongated hollow tubular conductive gasket with adhesive. 
     
     
       7. The apparatus defined in  claim 6  wherein the engagement structure comprises a sheet metal member. 
     
     
       8. The apparatus defined in  claim 7  further comprising a curved strip of material attached to the elongated hollow tubular conductive gasket with adhesive. 
     
     
       9. The apparatus defined in  claim 1  wherein the elongated hollow tubular conductive gasket has a length and has regions with different lateral dimensions along the length. 
     
     
       10. The apparatus defined in  claim 1  wherein the cable passes through the hollow air-filled cavity. 
     
     
       11. Apparatus, comprising:
 an elongated hollow tubular conductive gasket having a hollow air-filled interior cavity, wherein the elongated hollow tubular conductive gasket comprises a gasket wall structure that extends around the hollow air-filled interior cavity and wherein the gasket wall structure comprises conductive fabric; and 
 at least one cable that passes through the hollow-air filled cavity, wherein the cable comprises a transmission line cable coupled to at least one antenna; and 
 at least one flap of the conductive fabric that covers at least part of the transmission line cable. 
 
     
     
       12. An apparatus, comprising:
 opposing conductive structures; and 
 an elongated hollow tubular conductive gasket that is configured to form an electrical path when compressed between the opposing conductive structures, wherein the elongated hollow tubular conductive gasket has a conductive gasket wall configured to follow a curved path and wherein the conductive gasket wall comprises openings that facilitate bending of the conductive gasket wall to follow the curved path, wherein the elongated hollow tubular conductive gasket comprises a plurality of hollow conductive gasket segments, wherein the hollow conductive gasket segments are formed from a patterned sheet of conductive material, and wherein the patterned sheet of conductive material includes a curved spine portion and integral protrusions that extend from the curved spine portion. 
 
     
     
       13. The apparatus defined in  claim 12  wherein the conductive material comprises conductive fabric. 
     
     
       14. An apparatus, comprising:
 opposing conductive structures; 
 an elongated hollow tubular conductive gasket that is configured to form an electrical path when compressed between the opposing conductive structures, wherein the elongated hollow tubular conductive gasket has a conductive gasket wall configured to follow a curved path and wherein the conductive gasket wall comprises openings that facilitate bending of the conductive gasket wall to follow the curved path, wherein the elongated hollow tubular conductive gasket is at least partly surrounded by the conductive gasket wall, wherein the elongated hollow tubular conductive gasket extends along a curved longitudinal axis, wherein the conductive gasket wall extends around the curved longitudinal axis, wherein the conductive gasket wall has an inner surface and an outer surface and has opposing first and second edge portions that run parallel to the curved longitudinal axis and wherein the inner surface of the conductive gasket wall in the first edge portion is attached to the inner surface of the conductive gasket wall in the second edge portion with adhesive; and 
 at least one cable that passes through the elongated hollow tubular conductive gasket. 
 
     
     
       15. The apparatus defined in  claim 14  wherein the at least one cable comprises a plurality of cables that pass through the elongated hollow tubular conductive gasket. 
     
     
       16. The apparatus defined in  claim 14  further comprising a flap in the gasket wall that is configured to cover the at least one cable.

Description:
BACKGROUND 
     This relates generally to electronic devices and, more particularly, to conductive gaskets. 
     Conductive gaskets are used in electronic devices to short conductive structures together. For example, a conductive component such as a portion of a display or antenna may be electrically coupled to a conductive member by compressing a conductive gasket between the component and conductive member. This may short the conductive component to the conductive member, thereby grounding the conductive component and reducing interference in the electronic device. 
     Conductive gaskets are typically formed from foam that is wrapped in a conductive fabric. During assembly, the foam is compressed between the structures that are being shorted together. The foam attempts to return to its original uncompressed shape, thereby biasing the conductive fabric against the conductive structures. 
     It can be challenging to use foam gaskets. The biasing forces produced by compressed foam may tend to disassemble parts and may create undesired stresses. To ensure adequate mechanical tolerances, it may be necessary to use generously sized foam thicknesses. Overcoming the strong biasing forces that may result from the use of thick foam can be difficult and can force a designer to make undesired compromises when constructing an electronic device. The use of solid gaskets such as fabric covered foam gaskets may also reduce the amount of space available for other components in an electronic device. 
     It would therefore be desirable to be able to provide improved conductive gaskets for use in electronic devices. 
     SUMMARY 
     Electronic devices may be provided with conductive structures such as displays and conductive housing walls. Conductive gaskets may be used to form electrical paths between opposing conductive structures in an electronic device. During device assembly, a conductive gasket may be compressed between opposing conductive structures. The compressed conductive gasket may press outwards against the conductive structures, thereby forming an electrical pathway between the conductive structures. 
     A conductive gasket may be formed from a conductive gasket wall structure. The conductive gasket wall structure may surround and at least partly enclose an air-filled cavity. 
     Conductive gasket wall structures may be formed from conductive fabric, metal coated on dielectric sheets, or other conductive wall structures. Conductive fabric may be formed from metal fibers, dielectric fibers coated with metal, combinations of conductive fibers and fibers that are not conductive, or other suitable fibers. 
     A conductive gasket may have an elongated shape such as a tubular shape that is characterized by a longitudinal axis. The longitudinal axis may follow a straight path or a curved path. To facilitate bending of a hollow conductive gasket to follow a curved path, the wall structures of the gasket may be provided with openings. Openings may also be formed to create air passageways and passageways for cables. If desired, cables may be routed along the interior of a hollow gasket. Cables that run parallel to a gasket may be held in place along the exterior of the gasket using flaps of gasket wall material. 
     Sheet metal clips and other engagement structures may be attached to a conductive gasket using adhesive. In a curved gasket, a strip of curved material may be attached along the wall of the gasket using adhesive. 
     Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device with conductive gasket structures in accordance with an embodiment of the present invention. 
         FIG. 2  is a cross-sectional side view of illustrative conductive gaskets within an illustrative electronic device in accordance with an embodiment of the present invention. 
         FIG. 3  is a top view of an illustrative electronic device with curved and straight elongated conductive gaskets in accordance with an embodiment of the present invention. 
         FIG. 4  is a perspective view of an illustrative tube-shaped conductive gasket compressed between two opposing conductive structures in accordance with an embodiment of the present invention. 
         FIG. 5  is a diagram of illustrative fibers in a conductive fabric gasket in accordance with an embodiment of the present invention. 
         FIG. 6  is a cross-sectional view of a fiber such as a solid fiber in a conductive fabric gasket in accordance with an embodiment of the present invention. 
         FIG. 7  is a cross-sectional view of a fiber coated with a conductive material such as metal in a conductive fabric gasket in accordance with an embodiment of the present invention. 
         FIG. 8  is a diagram of a conductive fabric having conductive fibers and other fibers in accordance with an embodiment of the present invention. 
         FIG. 9  is a cross-sectional view of a portion of a hollow gasket structure in which a gasket wall is formed from a single layer of material such as a layer of conductive foil or conductive fiber in accordance with an embodiment of the present invention. 
         FIG. 10  is a cross-sectional view of a portion of a hollow gasket structure in which a gasket wall is formed from a conductive outer layer of material such as a layer of conductive foil or conductive fiber and an inner support layer such as a layer of plastic or foam that lines the inner surface of the conductive outer layer in accordance with an embodiment of the present invention. 
         FIG. 11  is a cross-sectional view of a portion of a hollow gasket structure in which a gasket wall is formed from a conductive outer layer of material such as a metal coating on an inner layer such as a dielectric layer formed from plastic in accordance with an embodiment of the present invention. 
         FIG. 12  is a cross-sectional view of a conductive gasket having a P-shaped cross section in accordance with an embodiment of the present invention. 
         FIG. 13  is a cross-sectional view of a conductive gasket having an O-shaped cross section in accordance with an embodiment of the present invention. 
         FIG. 14  is a cross-sectional view of a portion of a conductive gasket having a C-shaped cross section in accordance with an embodiment of the present invention. 
         FIG. 15  is a perspective view of a curved hollow conductive gasket having openings to facilitate bending in accordance with an embodiment of the present invention. 
         FIG. 16  is a perspective view of a curved hollow conductive gasket of the type shown in  FIG. 15  having an upper surface that has been covered with a curved strip of material in accordance with an embodiment of the present invention. 
         FIG. 17  is a diagram showing how openings may be formed along the length of a hollow conductive gasket to form a curved hollow conductive gasket in accordance with an embodiment of the present invention. 
         FIG. 18  is a top view of an illustrative hollow tube of conductive material that may be used in forming a conductive gasket in accordance with an embodiment of the present invention. 
         FIG. 19  is a top view of the hollow tube of  FIG. 18  following formation of laterally opposed openings in the sides of the tube to promote bending in accordance with an embodiment of the present invention. 
         FIG. 20  is a top view of the hollow tube of  FIG. 19  following bending of the tube to form a curved hollow conductive gasket in accordance with an embodiment of the present invention. 
         FIG. 21  is a diagram showing how a sheet of conductive gasket wall material may be formed into a segmented curved gasket with a hollow tube shape in accordance with an embodiment of the present invention. 
         FIG. 22  is a perspective view of an illustrative hollow gasket though which cables have been routed in accordance with an embodiment of the present invention. 
         FIG. 23  is a perspective view of a hollow gasket having a portion that is used in covering part of a cable in accordance with an embodiment of the present invention. 
         FIG. 24  is a cross sectional view of a hollow gasket of the type shown in  FIG. 23  in which part of the gasket has been used in covering a cable that runs parallel to the gasket in accordance with an embodiment of the present invention. 
         FIG. 25  is a perspective view of another illustrative configuration that may be used for a hollow conductive gasket having a portion that is used in covering a cable that runs parallel to the gasket in accordance with an embodiment of the present invention. 
         FIG. 26  is a cross sectional side view of a hollow gasket of the type shown in  FIG. 25  having a flap of material that covers part of a cable that runs parallel to the gasket in accordance with an embodiment of the present invention. 
         FIG. 27  is a perspective view of a conductive gasket having different diameters at different locations along the length of the conductive gasket in accordance with an embodiment of the present invention. 
         FIG. 28  is a perspective view of a conductive gasket such as a straight conductive hollow gasket having openings that create air passageways through the walls of the gasket in accordance with an embodiment of the present invention. 
         FIG. 29  is a perspective view of a conductive gasket structure having wall structures with perforations in accordance with an embodiment of the present invention. 
         FIG. 30  is a cross-sectional view of a conductive gasket to which a member such as a clip structure has been attached in accordance with an embodiment of the present invention. 
         FIG. 31  is a top view of a conductive gasket and associated cables of the type that may be used in the electronic device of  FIG. 1  in accordance with an embodiment of the present invention. 
         FIG. 32  is a perspective view of a segmented conductive gasket that has been formed from interlocked gasket structures in accordance with an embodiment of the present invention. 
         FIG. 33  is a side view of a pair of interlocked gasket segments that may be used in a chain of segmented conductive gaskets of the type shown in  FIG. 32  in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices may be provided with antennas and other wireless communications circuitry. The wireless communications circuitry may be used to support wireless communications in wireless communications bands such as wireless local area network bands, cellular telephone bands, satellite navigation system bands, and other communications bands. Electronic device may also contain electronic components such as displays. When operating an electronic device, it is often desirable to short together conductive structures. For example, it may be desirable to ground a portion of a display or a portion of an antenna to a conductive housing structure. By shorting together the conductive structures, electromagnetic interference (EMI) within an electronic device may be reduced. Conductive structures may also be shorted together to reduce the likelihood of component damage during electrostatic discharge events and to ensure proper grounding for other device functions. 
     The conductive structures that are being shorted together in an electronic device are often separated by an air gap. A conductive gasket structure may be interposed between opposing conductive structures to form a shorting path. The conductive gasket structure may be configured to span the air gap between the opposing conductive structures when the conductive structures and gasket structures are assembled together into an electronic device. 
     A conductive gasket structure may be compressed between opposing conductive structures during device assembly. Excessive restoring force from the compressed gasket structure may be avoided by using hollow gasket arrangements and/or gasket configurations that include relatively weak internal biasing structures. Examples of weak internal biasing approaches include the use of hollow gaskets, the use of gaskets that are partially hollow, the use of gaskets that are only partly filled with foam, the use of gaskets filled with plastic wool, the use of corrugated internal biasing structures, and the use of other biasing structures that contain relatively large amounts of air so that the interior cavity regions within the gaskets are at least partly air filled. 
     An illustrative electronic device of the type that may be provided with one or more conductive gaskets is shown in  FIG. 1 . Electronic device  10  may be a computer such as a computer that is integrated into a display such as a computer monitor. Electronic device  10  may also be a laptop computer, a tablet computer, a somewhat smaller portable device such as a wrist-watch device, pendant device, headphone device, earpiece device, or other wearable or miniature device, a cellular telephone, a media player, or other electronic equipment. Illustrative configurations in which electronic device  10  is a computer formed from a computer monitor are sometimes described herein as an example. In general, electronic device  10  may be any suitable electronic equipment. 
     Conductive gaskets may be formed in device  10  in any suitable location such as locations  18 . Locations  18  may include, for example, edge locations that run parallel to the four edges of device  10  and corner locations at the upper or lower corners of device  10  (as examples). Device  10  may include conductive structures that are electrically shorted together using conductive gaskets. The conductive structures may include conductive housing structures, conductive structures such as metal traces on dielectric carriers, conductive structures that are parts of display modules (e.g., metal chassis structures), metal traces in flexible printed circuits and rigid printed circuits, metal foil supported by dielectric carrier structures, wires, cables, and other conductive materials. 
     Device  10  may include a display such as display  14 . Display  14  may be mounted in a housing such as electronic device housing  12 . Housing  12  may be supported using a stand such as stand  16  or other support structure. 
     Housing  12 , which may sometimes be referred to as a case, may be formed of plastic, glass, ceramics, fiber composites, metal (e.g., stainless steel, aluminum, etc.), other suitable materials, or a combination of these materials. In some situations, parts of housing  12  may be formed from dielectric or other low-conductivity material. In other situations, housing  12  or at least some of the structures that make up housing  12  may be formed from metal elements. 
     Display  14  may be a touch screen that incorporates capacitive touch electrodes or other touch sensor components or may be a display that is not touch sensitive. 
     A cross-sectional side view of device  10  is shown in  FIG. 2 . As shown in  FIG. 2 , display  14  may include a transparent display cover layer such as display cover layer  14 A. Display cover layer  14 A may be formed from a clear glass layer, a transparent layer of plastic, or other transparent material. Display  14  may include display structures  14 B. Display structures  14 B may include an array of display pixels for displaying images for a user. Display cover layer  14 A may be used to protect display structures  14 B and, if desired, touch sensor structures in display  14 . Display structures  14 B may include display pixels formed from light-emitting diodes (LEDs), organic LEDs (OLEDs), plasma cells, electrophoretic display structures, electrowetting display structures, liquid crystal display (LCD) components, or other suitable display pixel structures. 
     As shown in the example of  FIG. 2 , conductive gaskets such as conductive gaskets  20  may be used to electrically connect opposing conductive structures in device  10 . In the  FIG. 2  configuration, gaskets  20  are being used to electrically connect display structures  14 B to housing  12 . Display structures  14 B may include conductive structures such as a metal chassis member that surrounds and encloses the lower portion of display structures  14 B. Housing  12  may include metal walls. Gaskets  20  in regions  18  may be used in shorting the metal chassis member of display  14  or other conductive component structures to conductive housing  12  or may otherwise be used in shorting together conductive structures in device  10 . If desired, gaskets  20  may be used to short an antenna ground (e.g., an antenna cavity wall) in antennas such as antenna  22  to opposing conductive structures such as display structures  14 B and/or conductive housing  12 . 
     By forming conductive interfaces that fill gaps between opposing conductive structures such as display structures  14 B and housing  12  and by otherwise grounding conductive structures within device  10 , potential pathways for electromagnetic interference within device  10  may be reduced or eliminated. For example, by forming a conductive seal between display structures  14 B and housing  12 , potential pathways for electromagnetic interference between components  26  on printed circuit  24  and components such as antenna  22  may be blocked. Components  26  may include display driver circuitry, processors, memory, communications circuitry such as wireless transceiver circuitry, and application-specific integrated circuits. By blocking the air gap between components  14 B and housing  12 , a reduced number of interfering signals may pass between antenna  22  and components  26 , thereby improving wireless performance in device  10 . In general, conductive gaskets such as conductive gaskets  20  of  FIG. 2  may be used to short together any two or more conductive structures in device  10 . The illustrative configuration of  FIG. 2  is merely an example. 
       FIG. 3  is a top view showing how conductive gaskets  20  may have elongated shapes that are straight (e.g., straight gaskets  20 S) and curved (e.g., curved gaskets  20 C). In the illustrative configuration of  FIG. 3 , gaskets  20  have been placed so that they run parallel to the straight edges and curved corners of housing  12 . If desired, gaskets  20  may be placed within other locations in device  10 . The configuration of  FIG. 3  is merely illustrative. 
     Gaskets  20  may have a hollow tube shape or other configuration that is compressible, but that does not exert excessive restoring forces upon structures in device  10  following assembly. An illustrative arrangement in which a hollow tube-shaped conductive gasket has been compressed between two opposing conductive structures is shown in  FIG. 4 . As shown in  FIG. 4 , gasket  20  may be hollow (i.e., gasket  20  may have a gasket wall such as wall  38  that extends around air-filled cavity  78 , so that the interior of gasket  20  is filled only with air. If desired, some of the interior of gasket  20  may be provided with internal support structures (e.g., structures formed from foam biasing layers, foam structures with undulating surfaces, corrugated sheets of biasing material, or other structures that support cavity wall  38 ). 
     Conductive device structures such as structures  30  and  32  of  FIG. 4  may be moved towards each other during device assembly operations. As structure  30  is moved downwards in direction  34  towards structure  32  and/or as structure  32  is moved upwards in direction  36  towards structure  30 , conductive gasket  20  may be compressed between structures  30  and  32 . When compressed, gasket wall  38  may press outwards against conductive structures  30  and  32 , thereby forming an electrical pathway between structures  30  and  32 . For example, the upper portion of gasket wall  38  may press upwards in direction  40  against lower surface  48  of structure  30  in region  44  and the lower portion of gasket wall  38  may press downwards in direction  42  against upper surface  50  of structure  32 . Relatively large contact patches (i.e., the areas in regions  44  and  46 ) may be used in forming connections to structures  30  and  32 , thereby minimizing contact resistance. 
     Gaskets such as gasket  20  may have any suitable shape. In the example of  FIG. 4 , gasket  20  has an elongated hollow tube shape that extends along longitudinal axis  52 . If desired, conductive gaskets such as gasket  20  may be formed with other shapes (e.g., circular outlines, rectangular outlines, square outlines) and may have other cross-sectional shapes. Gaskets  20  may have shapes that accommodate internal biasing structures while leaving room for air-filled cavities within the interior of gasket  20 , may have shapes that are completely hollow at one location along their length but that are not completely hollow at another location along their length, etc. The elongated tubular shape of conductive gasket  20  of  FIG. 4  is merely illustrative. 
     Conductive material for gasket wall  38  may be formed from a sheet of metal, a metal coating on a sheet of dielectric, metal fibers, metal-coated fibers, or other suitable conductive material. As shown in  FIG. 5 , conductive gasket  20  (e.g., gasket wall  38 ) may be formed from fibers such as fibers  154  (e.g., gasket wall structure  38  may be formed from a layer of conductive fabric). Fibers  154  may include metal fibers, plastic fibers coated with metal, glass fibers, carbon fibers, organic fibers, inorganic fibers, fibers formed from other materials, and fibers formed from two or more of these materials. Fibers  154  may have circular cross-sectional shapes, oval cross-sectional shapes, rectangular cross-sectional shapes, square cross-sectional shapes, triangular cross-sectional shapes, and other cross-sectional shapes. 
     As shown in  FIG. 6 , fibers  154  in gasket wall  38  may be formed from a solid material such as material  156 . Material  156  may be, for example, a conductive material such as metal. As shown in  FIG. 7 , fibers  154  may include multiple materials such as inner material (core)  158  and outer material (coating)  160 . Core  158  may be, for example, a dielectric such as glass, plastic, or ceramic, or may be a conductive material such as metal (as examples). Outer layer  160  may be formed from a conductive material such as metal (as an example). Layer  160  may be formed on each of fibers  154  before fibers  154  are used in forming conductive fabric or other fiber-based material for gasket wall  38  or may be deposited as a coating on fibers  154  after fibers  154  have been used to form conductive fabric or other fiber-based material for gasket wall  38  (e.g., after fibers  154  have been woven into a fabric layer). 
     As shown in  FIG. 8 , gasket wall  38  (e.g., a fabric sheet for forming wall  38 ) may include multiple fibers such as fibers  154  and fibers  162 . Fibers  154  may include conductive fibers such as solid metal fibers and/or dielectric fibers coated with metal or other conductive fibers. Fibers  162  may be formed from plastic, glass, or other non-conductive material. For example, fibers  162  may be formed from solid dielectric material with a circular cross-sectional shape such as material  156  in  FIG. 6 . If desired, fabric gasket wall structures such as structures  38  of  FIG. 8  may be formed from three or more different types of fibers (e.g., conductive fibers and/or dielectric fibers). The example of  FIG. 8  in which structures  38  include two types of fiber is merely illustrative. 
       FIG. 9  is a cross-sectional view of a portion of conductive gasket structure  20  in which gasket wall  38  has been formed from a single layer of material. Gasket wall  38  may, for example, be formed from a woven conductive fabric with solid conductive fibers and/or fibers with two or more layers of material such as an inner core covered with an outer conductive layer of metal or may be formed from a sheet of flexible metal (e.g., metal foil). 
       FIG. 10  is a cross-sectional view of a portion of conductive gasket structure  20  in which gasket wall  38  has been formed from a conductive outer layer of material (layer  164 ) and one or more inner layers of material such as layer  166 . Outer layer  164  may be, for example, a conductive fabric such as a fabric formed from solid conductive fibers and/or fibers with two or more layers of material such as an inner core covered with an outer conductive layer of metal. If desired, some or all of outer layer  164  may be formed from a sheet of flexible metal (e.g., metal foil). 
     Outer layer  164  of conductive gasket structure  20  may be attached to one or more inner layers such as layer  166 . For example, outer layer  164  may be attached to inner layer  66  using adhesive layer  168 . Adhesive layer  168  may be formed from a pressure sensitive adhesive material, a conductive adhesive material, or other suitable adhesive. Inner layer  166  may line the interior surface of layer  164  and may provide layer  164  with additional strength and resiliency. Inner layer  166  may be formed from a flexible layer of metal, a flexible layer of fabric, a flexible layer of plastic, a flexible layer of foam, a flexible layer of one or more other materials, or a flexible layer formed from two or more such layers. If desired, additional layers may be stacked below layer  166  (e.g., layer  166  may be lined with one or more additional layers of fabric, one or more additional layers of plastic, one or more additional layers of foam, etc.). 
     As shown in the cross-sectional view of  FIG. 11 , wall  38  of conductive gasket structure  20  may have a conductive coating such as coating  170  that is formed on the outer surface of a flexible support layer such as layer  172 . Coating  170  may be, for example, a layer of metal or other conductive material. Layer  172  may be formed from fabric, a layer of plastic, a layer of metal, or a layer formed from one or more other dielectric and/or conductive materials. Coating  170  may be formed on the outer surface of sheet  172  using physical vapor deposition, using chemical vapor deposition, by spraying, by electrochemical deposition (e.g., by electroplating), or by using other suitable deposition techniques. 
       FIG. 12  is a cross-sectional view of an illustrative hollow conductive gasket having a P-shaped cross section. As shown in  FIG. 12 , gasket  20  may be compressed between opposing conductive structures such as conductive structures  30  and  32 . Conductive gasket wall  38  may extend around longitudinal axis  52 . Gasket  20  may have a main portion such as portion  64  in which gasket wall  38  surrounds air-filled cavity  78  (e.g., an elongated air-filled cavity that extends along the length of gasket  20 ). Gasket  20  may also have a tail portion such as tail portion  62 . Gasket wall  38  may have opposing edges such as edges  54  and  56 . In tail region  62 , edges  54  and  56  may be attached to conductive structure  32  using adhesive  58 . 
     Gasket wall  38  may have an inner surface and an opposing outer surface. In region  62 , the inner surface of a portion of gasket wall  38  at edge  54  may face the inner surface of a portion of gasket wall  38  at edge  56 . The outer surface of gasket wall  38  may be attached to the surface of conductive structure  32  using adhesive  58 . During assembly operations, a tool (e.g., a heated member or other suitable member) may be used to press downwards on the layers of gasket wall  38  in region  62 , thereby causing adhesive  58  to attach gasket wall  38  and gasket  20  to conductive structure  32 . Other types of assembly techniques may be used to form gasket  20  and to attach gasket  20  to conductive structures in device  10 , if desired. The configuration of  FIG. 12  is merely illustrative. 
       FIG. 13  is a cross-sectional view of gasket  20  in a configuration in which gasket wall  38  has been wrapped around longitudinal axis  52  to form an O-shaped cross section for gasket  20 . Adhesive  58  may be used to attach edges  54  and  56  of gasket wall  38  to conductive structures  38  in a configuration in which the outer surface of edge  54  is attached to the inner surface of edge  56  and in which the outer surface of edge  56  is attached to structures  32 . If desired, other types of seams may be formed to create a gasket with an O-shaped cross-section (e.g., joints with abutting edges that do not overlap). The configuration of  FIG. 13  is provided as an example. 
     In the illustrative arrangement of  FIG. 14 , conductive gasket wall  38  has been configured to form a C-shaped gasket cross section. Gasket wall  38  has a portion that extends around longitudinal axis  52  and forms an upper boundary for air-filled cavity  78 . A lower boundary for air-filled cavity  78  may be formed by part of conductive structure  32  or other materials (e.g., a separate sheet of gasket wall material, conductive tape, a strip of metalized plastic etc.). Gasket wall  38  may have a left-hand edge such as edge  54  that has an inner surface attached to conductive structure  32  using adhesive  58 . Gasket wall  38  may also have a right-hand edge such as edge  56  that has an inner surface attached to conductive structure  32  using adhesive  58 . 
     When forming gaskets such as straight elongated hollow conductive gaskets  20 S of  FIG. 3 , gasket wall  38  may form a straight hollow cylinder with a P-shaped cross section, an O-shaped cross section, a C-shaped cross section, or a cross section with other suitable shapes. Curved gaskets such as curved hollow conductive gaskets  20 C of  FIG. 3  may be formed by bending a hollow cylinder of gasket wall material. To help reduce or eliminate wrinkles in gasket wall material  38  in configurations in which a portion of gasket  20  follows a curved path, slits or other openings may be formed in the gasket at various locations along its length (e.g., at intervals along the curved portion of gasket  20 ). 
     An illustrative curved gasket with slits (i.e., a gasket that may serve as one of curved gaskets  20 C of  FIG. 3 ) is shown in  FIG. 15 . As shown in  FIG. 15 , curved gasket  20  may have an elongated shape that extends along curved longitudinal axis  52 . Gasket wall  38  may be configured to have a P-shaped cross section as described in connection with  FIG. 12  or may be configured to have other suitable cross-sectional shapes (e.g., an O-shaped cross section of the type shown in  FIG. 13 , a C-shaped cross section of the type shown in  FIG. 14 , etc.). To reduce wrinkling in gasket wall  38  as gasket  20  is bent into the curved shape of  FIG. 15 , gasket  20  may be provided with openings  80  at various locations along its length (i.e., at various positions along longitudinal axis  52 ). 
     Openings  80  may be formed by making straight cuts into gasket wall  38 , so that edges  82  and  84  of each opening  80  part from each other to form an opening (i.e., a slit) without removing any of the material of gasket wall  38  or, if desired, material may be removed from gasket wall  38  to form openings  80 . 
     If desired, portions of the exposed surface of gasket  20  such as the uppermost surface of gasket wall  38  may be covered with one or more layers of additional material. As shown in  FIG. 16 , for example, gasket  20  may be covered with a curved piece of material such as curved strip  86 . Strip  86  may be formed from a cut sheet of plastic, a metal layer, a layer formed from one or more different materials, or other suitable material. Adhesive such as adhesive  88  may be used in attaching curved strip  86  (e.g., a curved plastic strip) to gasket wall  38 . Adhesive  88  may be conductive adhesive to ensure formation of a satisfactory low resistance electrical path between conductive structures  30  and  32  when curved gasket  20  of  FIG. 16  is installed within device  10 . Straight strips of material  86  may be used to cover straight portions of gasket  20 . 
       FIG. 17  is a diagram showing how openings may be formed along the length of a hollow conductive gasket to form a curved hollow conductive gasket. To facilitate bending, a cutting tool such as cutting tool  92  of  FIG. 17  may be used to form openings in tube-shaped gasket structure (e.g., a hollow cylindrical tube of conductive gasket wall material such as gasket wall  38 ). Cutting tool  92  may include one or more cutting blades, laser cutting equipment, water-jet cutting equipment, or other equipment for forming cuts in the material of gasket wall  38 . As shown in  FIG. 17 , the cuts that are made in the walls of tube  90  may be used to form a tube with openings  80  such as tube  94 . Openings  80  may be formed by creating cuts with or without removing some of the material of gasket wall  38 . For example, cutting tool  92  may be used to form straight cuts or cuts that remove pieces of gasket wall  38 . 
     Following formation of openings  80  in tubular structure  94  of gasket wall material  38 , assembly tools  96  may be used in forming curved gasket  20  and installing curved gasket  20  in device  10 . Assembly tools  96  may, for example, include computer-controlled positioners and other equipment for bending tube  94  to form curved gasket  20 , may include equipment for applying adhesive such as adhesive  58  of  FIGS. 12 ,  13 , and  14 , and may otherwise be used in shaping tube  94  into curved gasket  20  of  FIG. 17 . As shown in  FIG. 17 , curved gasket  20  may have an elongated shape that is characterized by longitudinal axis  52 . Openings  80  in curved gasket  20  may help gasket  20  form a curved shape within device  10  (e.g., so that gasket  20  may serve as one of curved gaskets  20 C of  FIG. 3  or may otherwise be used in coupling curved conductive structures) without wrinkling gasket wall  38 . 
     If desired, curved conductive gaskets may be provided with openings on opposing sides (i.e., in laterally opposing sidewall portions of gasket wall  38 ). Initially, gasket wall material  38  may be formed into a tubular shape such as tubular shape  98  of  FIG. 18 . A cutting tool such as cutting tool  92  of  FIG. 17  may be used to cut openings in laterally opposing sides of tube  98 , as shown by openings  80 A and  80 B in tubular gasket structure  100  of  FIG. 19 . Openings  80 A may be formed along one side of gasket wall material  38  and laterally opposing openings  80 B may be formed on an opposing side of gasket wall material  38 . Following formation of tubular structure  100  by forming openings  80 A and  80 B in gasket wall  38 , an assembly tool such as assembly tool  96  of  FIG. 17  may be used to bend tubular structure  100  to form curved gasket  20  of  FIG. 20 . As shown in  FIG. 20 , openings  80 A may be located along the outer edge of curved gasket  20  and may help allow gasket wall material  38  to expand to accommodate the relatively longer length of the outer edge of gasket  20  without stretching gasket wall material  38 . Openings  80 B may be located along the opposing (inner) edge of curved gasket  20  and may help accommodate the curvature of gasket  20  (i.e., the relatively shorter length of the inner edge of gasket  20 ) without compressing to form wrinkles in gasket wall structure  38 . 
       FIG. 21  is a diagram showing how a sheet of conductive gasket wall material may be formed into a segmented curved gasket with a hollow tube shape. Initially, a roll of gasket wall material  38  may be obtained such as roll  102 . A cutting tool such as cutting tool  104  may be used to cut gasket wall material  38  into a pattern suitable for forming a segmented curved gasket. As shown in  FIG. 21 , for example, cutting tool  104  may be used to cut a sheet of gasket wall material  38  to form patterned gasket wall material  106 . 
     Patterned gasket wall material  106  may have a pattern with a curved spine such as spine  108 . Spine portion  108  of patterned gasket wall material  106  may have a curved shape that matches the desired curvature for a finished curved gasket. Integral laterally protruding portions such as flap structures  110  may protrude outwardly from spine region  108  in directions  112 . Laterally protruding flaps such as flap structures in regions  114  may protrude inwardly from spine  108  in directions  116 . Cutting tool  104  may include die stamping equipment, one or more cutting blades, laser-cutting equipment, water-jet cutting equipment, or other equipment for cutting gasket wall sheet  38  to form patterned gasket wall sheet  106 . 
     Following formation of patterned gasket wall material  106  with tool  104 , an assembly tool such as wrapping tool  118  may be used to wrap flaps  110  and  114  into cylindrical gasket segments  120 . Tool  118  may include computer-controlled actuators, equipment for dispensing adhesive, and other equipment for wrapping portions of structure  106  and for using adhesive to attach opposing portions of structure  106  to each other. Tool  118  may, for example, use adhesive to attach the tips of each flap  110  to the tip of a respective adjacent one of flaps  114 . Curling flaps  110  and  114  onto each other and attaching the tips of the flaps to each other in this way may create a segmented curved conductive hollow gasket such as gasket  20  of  FIG. 21 . As shown in  FIG. 21 , gasket  20  may include multiple segments  120 , each segment being formed by one of flaps  114  and one of flaps  110 . Segments  120  are separated from each other by openings  80  and may be held together by integral spine portion  108 . Because spine  108  has a curved shape, gasket wall  38  (i.e., patterned material  106 ) may be wrapped to form curved gasket  20  of  FIG. 21  without introducing excessive wrinkles into gasket wall  38 . 
     Electronic device  10  may contain electrical cables such as radio-frequency transmission lines (e.g., coaxial cables, transmission lines formed on flexible printed circuit substrates, etc.), signals buses (e.g., wires for forming analog signal paths, wires for forming digital signal paths), wires for conveying power supply signals in device  10 , and other conductive paths. Cables may be formed from solid strands of metal covered with insulating coating, from wire that includes multiple wire filaments, from conductive traces on a flexible printed circuit or rigid printed circuit substrate, or from other conductive structures. 
     Space is often at a premium in electronic devices. To conserve space and reduce clutter in device  10 , cables can be routed through interior portions of hollow gaskets.  FIG. 22  is a perspective view of an illustrative configuration for hollow conductive gasket  20  showing how cables  122  may be routed through interior cavity region  78  within gasket wall  38  of gasket  20 . Cables  122  may be transmission lines, analog signal lines, digital signal lines, power supply lines, or other signal paths in device  10 . There are two cables  122  in the illustrative configuration of  FIG. 22  each of which runs parallel to longitudinal axis  52  of elongated conductive hollow gasket  20 . This is merely illustrative. In general, one of cables  122 , two of cables  122 , three or more of cables  122 , or any other suitable number of cables may be routed through air-filled cavity  78  of gasket  20 . Gasket  20  may have a straight shape or may be curved (e.g., by providing gasket  20  with openings  80 ). Cables  122  may enter and exit gasket  20  through the ends of gasket  20  or through side openings in gasket wall  38 . 
       FIG. 23  is a perspective view of conductive hollow gasket  20  in a configuration in which gasket  20  has a portion such as flap (flag)  124  that covers part of cable  122 . Flap  124  may be formed by cutting an opening in gasket wall  38  such as opening  126 . Opening  126  may be formed by cutting wall  38  along edges  128  and  130  and folding the cut portion of wall  38  downwards over cable  122 . With this type of arrangement, wire covering flap  124  may include two layers of wall material  38 : upper gasket wall layer  38 T and lower gasket wall layer  38 B, both formed from gasket wall  38 . Adhesive may be used to attach flap  124  to structures within device  10  (e.g., conductive structures), thereby securing cable  122  in place. 
       FIG. 24  is a cross sectional view of hollow gasket  20  of  FIG. 23  in which part of gasket  20  has been used in forming flap  124  for covering cable  122 . Cable  122  may run parallel to longitudinal axis  52  of elongated gasket  20 . Gasket  20  may be a straight gasket or a curved gasket and may have one or more flaps such as flap  124  along its length. As shown in  FIG. 24 , adhesive  58  (e.g., conductive adhesive) may be used in attaching flap  124  to conductive structure  32  over cable  122 . Adhesive  58  may also be used in attaching gasket wall  38  to conductive structure  32  in tail region  62  of gasket  20 . 
       FIG. 25  is a perspective view of another illustrative configuration that may be used to provide hollow conductive gasket  20  with cable-covering flaps. As shown in  FIG. 25 , flap  124  may be formed by cutting gasket wall  38  along edges  128 ,  130 , and  132 , thereby forming a single layer of wall material  38  (i.e., wall material  38 ′) for flap  124 . 
       FIG. 26  is a cross sectional side view of gasket  20  of  FIG. 25  showing how flap  124  (formed from gasket wall layer  38 ′) may be used to cover part of cable  122 . Adhesive  58  (e.g., conductive adhesive) may be used to attach flap  124  to conductive structure  32  over cable  122 . 
     If desired, different portions of conductive gasket  20  may have different diameters (e.g., to accommodate conductive structures with different air gap widths, etc.). As shown in  FIG. 27 , for example, gasket  20  may have regions such as regions  134  that are characterized by lateral dimension D 1 . Dimension D 1  may represent the diameter (largest lateral dimension) of gasket  20  in region  134 . Gasket  20  may also have regions such as regions  136  that are characterized by lateral dimension D 2 . Dimension D 2  may represent the diameter (largest lateral dimension) of gasket  20  in region  136  and may be different than dimension D 1 . For example, dimension D 2  may be larger than dimension D 1 . Regions such as regions  134  may alternate with regions such as regions  136  along the length (dimension parallel to longitudinal axis  52 ) of gasket  20 . In the illustrative configuration of  FIG. 27 , gasket  20  has regions with two different lateral dimensions (i.e., dimensions D 1  and D 2 ). If desired, gasket  20  may have three or more different types of regions each with a potentially different maximum lateral dimension (dimension perpendicular to longitudinal dimension  52 ). The configuration of  FIG. 27  in which gasket  20  has longitudinally spaced sections of two different diameters is merely illustrative. 
       FIG. 28  is a perspective view of a conductive gasket having openings  138  that create passageways such as passageways for air flow from one side of gasket  20  to another. As shown in  FIG. 28 , gasket  20  may be formed from gasket wall structures  38  that have been attached to conductive structure  32  using adhesive  58 . Gasket  20  may be configured to have a P-shaped cross-sectional shape or other suitable cross section. Openings  138  may be characterized by a length L that runs parallel to longitudinal axis  52  and a width W that is perpendicular to length L (as an example). The length L may, for example, be larger than width W. For example, L may be 0-20 mm, and W may be 0-10 mm, with L&gt;W. If desired, openings  138  may be formed on opposing sides of gasket  20 , as shown in  FIG. 28 , so that air may flow from one side of gasket  20  to the other (as an example). Openings  138  may also accommodate cables and other device structures. Openings  138  may be rectangular, circular, oval, may have shapes with straight edges, shapes with curved edges, or shapes with combinations of straight and curved edges. The rectangular shapes of openings  138  in gasket wall  38  of elongated conductive hollow gasket  20  are merely illustrative. 
     If desired, conductive gasket  20  may have gasket wall structures  38  that contain openings (e.g., circular opening or openings of other suitable shapes) such as perforations  138  of  FIG. 29 . 
     As shown in  FIG. 30 , gasket  20  may be provided with structures such as ancillary member  140 . Member  140  may be a bracket, a connector, or other structure. Member  140  may be, as an example, an engagement structure such as a clip for engaging other structures in device  10 . A clip or other engagement structure may receive a cable or may serve as a bracket that is configured to hold a component. Member  140  may, if desired, be configured to mate with a corresponding member that is attached to a structure in device  10  (e.g., member  140  may be a clip that attaches to mounting points within device  10  to facilitate attachment of gasket  20  within device  10 ). Members such as member  140  may be attached to gasket wall structure  38  in gasket  20  using adhesive  58  (e.g., conductive adhesive) or other suitable attachment mechanisms. Members such as member  140  may be formed from plastic, metal, glass, ceramic, carbon-fiber or other fiber-based composites, other materials or combinations of these materials. As an example, members such as member  140  may be formed from stamped sheet metal. 
     A top view of illustrative internal structures in a device such as device  10  of  FIG. 1  is shown in  FIG. 31 . Internal structures  142  may include antennas  144  such as a wireless local area network antenna (e.g., an antenna having a cavity formed form a circular metal can) and cellular telephone antennas (e.g., antennas formed from metal traces on plastic carriers). Cables  122  may include radio-frequency transmission lines for coupling antennas  144  to radio-frequency transceiver circuitry such as radio-frequency transceiver circuitry in components  26  on printed circuit  24  of  FIG. 2 . Gasket  20  may have openings such as openings  80  to facilitate bending of gasket  20  in curved sections of gasket  20 . Openings such as opening  80 ′ may be formed in gasket  20  to accommodate cables  122  (e.g., to allow cable  122  to pass from one side of gasket  20  to another or to enter or exit a length of gasket  20 ). 
     In the illustrative example of  FIG. 21 , segmented gasket  20 , includes a spine region such as region  108  that is integral with protruding portions  1120  and  114 . If desired, a segmented gasket may be formed by creating individual box-shaped gasket segments that are interconnected through the use of separate interleaved gasket wall structures. This type of arrangement is shown in  FIG. 32 . As shown in  FIG. 32 , conductive hollow gasket  20  may be formed from interlocked segments  146 . Segments  146  may each be formed from a folded piece of gasket wall material  38  (e.g., a folded patterned sheet of gasket wall material  38 ). Rather than using an integral spine portion such as spine  108 , gasket segments  146  may be interconnected using flaps of gasket material or other structures that engage one another but that are separate from one another. As shown in  FIG. 33 , for example, gasket segment  146 - 1  may have flap  150  and gasket segment  146 - 2  may have flap  148 . Flaps  150  and  148  are not part of the same piece of material, but may engage one another to interlock segments  146 - 1  and  146 - 2 . By interlocking multiple segments  146  in this way, a straight or curved chain of segments  146  may be used to form gasket  20  ( FIG. 32 ). 
     In general, gaskets with wall openings to form air passageways, gaskets with wall perforations, gaskets with flaps cut out of portions of a gasket wall, gaskets with attached clips or other members, and gaskets with openings to facilitate bending may be formed using a straight configuration in which the gaskets runs parallel to a straight longitudinal axis or may be formed using a curved configuration in which the gaskets run parallel to a curved longitudinal axis and thereby follow a curved path. Gaskets such as these may also be formed that have a combination of these features and a combination of straight and curved portions. 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.

Metadata:
Filing Date: 20120619
Publication Date: 20150630
Grant Date: 20150630
Priority Date: 20120619
Inventors: NGUYEN ANTHONY P.
TARKINGTON DAVID P.
JEZOIREK PETER N.
ZORKENDORFER RICO L.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K9/0015", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K9/0015", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 49754843