PATENT DOCUMENT

Publication Number: US-9730340-B1
Application Number: US-201514720502-A
Country: US
Kind Code: B1

Title: Electronic device with array of rotationally mounted components

Abstract:
An array of electrical components may be mounted in openings in an electronic device housing. Gaskets may be used to seal the electrical components to a housing wall. The housing wall may be planar or may have a cylindrical shape or other curved shape. The electrical components may be mounted to the housing wall by rotating the electrical components so that portions of the components bear against an inner surface of the housing wall. Component mounting structures that receive the electrical components may be used in mounting the electrical components. Component cover structures with openings may overlap the components. Engagement features may help prevent relative rotational motion between the electrical components and the housing wall of the electronic device.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a housing have a housing wall with an opening; and 
 an electrical component having a protrusion that bears against an inner surface of the housing wall and pulls the electrical component into the opening when the electrical component and protrusion are rotated about a rotational axis. 
 
     
     
       2. The electronic device defined in  claim 1  further comprising a ring-shaped gasket that is compressed between the electrical component and a portion of the housing wall to seal the component within the opening. 
     
     
       3. The electronic device defined in  claim 2  wherein the portion of the housing wall comprises a ridge in the housing that is formed within the opening. 
     
     
       4. The electronic device defined in  claim 3  wherein the electronic component has a circular periphery and a plurality of notches on the circular periphery. 
     
     
       5. The electronic device defined in  claim 3  wherein the ridge and an opposing portion of the electrical component have angled surfaces that drive the gasket radially outwards when the gasket is compressed between the electrical component and ridge. 
     
     
       6. The electronic device defined in  claim 3  wherein the protrusion and inner surface of the housing wall are configured to secure the electrical component within the opening when the electrical component is rotated about the axis by a quarter turn. 
     
     
       7. The electronic device defined in  claim 3  wherein the electrical component comprises a component selected from the group consisting of: a light source, a light detector, a speaker, and a sensor. 
     
     
       8. The electronic device defined in  claim 7  wherein the inner surface of the housing wall comprises a curved inner surface. 
     
     
       9. The electronic device defined in  claim 7  wherein the housing comprises a cylindrical housing and wherein the inner surface comprises a curved inner surface, wherein the opening comprises one of a plurality of openings in the housing wall, and wherein the electrical component comprises one of a plurality of electrical components in the plurality of openings. 
     
     
       10. An electronic device, comprising:
 a housing having a curved housing wall defining an opening and grooves arranged along a periphery of the opening; and 
 an electrical component having prongs that are received within the grooves in the opening of the curved housing wall, 
 wherein the housing defines radially recessed portions distributed along the periphery of the opening that release the prongs from the grooves in response to rotation of the electrical component. 
 
     
     
       11. The electronic device defined in  claim 10  wherein the electrical component comprises a component selected from the group consisting of: a light source, a light detector, a speaker, and a sensor. 
     
     
       12. The electronic device defined in  claim 11  further comprising a ring-shaped gasket that is compressed between peripheral portions of the electrical component and portions of the housing wall surrounding the opening. 
     
     
       13. The electronic device defined in  claim 10  wherein the opening is circular, wherein the housing is cylindrical, wherein the opening in the housing wall is one of a plurality of openings, and wherein the electrical components having prongs is one of a plurality of electrical components having prongs in the openings. 
     
     
       14. The electronic device defined in  claim 13  further comprising a guide structure that has an angled portion forming a guiding ramp that guides the electrical component into the opening without striking the housing wall. 
     
     
       15. An electronic device, comprising:
 a housing having a curved housing wall with a circular housing wall opening having an edge, wherein the housing comprises radial protrusions extending into the circular housing wall opening; 
 an electrical component in the circular housing wall opening; and 
 a retention member that holds the electrical component in the circular housing wall opening, wherein the retention member comprises a plurality of axial protrusions, each axial protrusion defining an opening that receives a corresponding one of the radial protrusions. 
 
     
     
       16. The electronic device defined in  claim 15  wherein the electrical component comprises a component selected from the group consisting of: a light source, a light detector, a speaker, and a sensor. 
     
     
       17. The electronic device defined in  claim 16  further comprising a ring-shaped gasket that is compressed between peripheral portions of the electrical component and portions of the housing wall along the edge of the circular housing wall opening, wherein the circular housing wall opening is one of a plurality of circular housing wall openings in the curved housing wall, and wherein the electrical component is one of a plurality of electrical components in the circular housing wall openings. 
     
     
       18. An electronic device, comprising:
 a housing having a curved housing wall with a circular housing wall opening and having grooves in the circular housing wall opening; 
 an electrical component in the circular housing wall opening having a cam structure; and 
 a rotating locking member that has prongs with tabs, wherein the rotating locking member is rotated so that the cam structure presses the prongs outwardly into the grooves and pulls the electrical component against the housing. 
 
     
     
       19. The electronic device defined in  claim 18  wherein the electrical component comprises a component selected from the group consisting of: a light source, a light detector, a speaker, and a sensor. 
     
     
       20. The electronic device defined in  claim 19  further comprising a ring-shaped gasket that is compressed between the electrical component and portions of the housing wall surrounding the circular housing wall opening. 
     
     
       21. The electronic device defined in  claim 20  wherein the circular housing wall opening is one of a plurality of circular housing wall openings in the curved housing wall, and wherein the electrical component is one of a plurality of electrical components in the circular housing wall openings. 
     
     
       22. An electronic device, comprising:
 a housing having a curved housing wall defining a housing wall opening and recesses extending radially outward from the housing wall opening; 
 an electrical component in the housing wall opening; 
 a component mounting structure having a cavity that receives the electrical component, wherein the component mounting structure is mounted to an interior surface of the curved housing wall and includes portions that cover the recesses; and 
 a component cover structure that is mounted to the curved housing wall covering the electrical component in the housing wall opening. 
 
     
     
       23. The electronic device defined in  claim 22  wherein the component cover structure has openings. 
     
     
       24. The electronic device defined in  claim 22  wherein the electrical component is screwed into the component mounting structure. 
     
     
       25. The electronic device defined in  claim 24  wherein:
 the electrical component comprises a component selected from the group consisting of: a light source, a light detector, a speaker, and a sensor; and 
 the circular housing wall opening is one of a plurality of circular housing wall openings in the curved housing wall. 
 
     
     
       26. An electronic device, comprising:
 a housing having a housing wall, wherein the housing wall has an opening and an engagement feature adjacent to the opening; 
 an electrical component that is mounted in the opening, wherein the electrical component has an electrical component engagement feature; 
 a component cover that covers the electrical component, wherein the component cover has a first engagement feature that mates with the engagement feature in the housing wall to prevent rotation of the component cover relative to the housing wall and wherein the component cover has a second engagement features that mates with the electrical component engagement feature to prevent rotation of the electrical component relative to the component cover and relative to the housing wall. 
 
     
     
       27. The electronic device defined in  claim 26  wherein the component cover has openings. 
     
     
       28. The electronic device defined in  claim 27  wherein the electrical component engagement feature comprises a notch and wherein the second engagement feature comprises a protrusion that is received within the notch. 
     
     
       29. The electronic device defined in  claim 27  wherein:
 the housing wall is a curved housing wall; 
 the electrical component comprises a component selected from the group consisting of: a light source, a light detector, a speaker, and a sensor; and 
 the opening comprises a circular housing wall opening that is one of a plurality of circular housing wall openings in the curved housing wall.

Description:
This application claims the benefit of provisional patent application No. 62/057,817, filed Sep. 30, 2014, which is hereby incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     This relates generally to electronic devices, and more particularly, to electronic devices with electronic components mounted to device housings. 
     Electronic devices include electronic components. Some components such as integrated circuits and batteries are mounted within interior portions of electronic device housings. Other components are mounted on the exteriors of housings. For example, components that emit or receive light or sound are often mounted in exposed locations on housings to facilitate proper operation of the components in supplying output and receiving input. 
     In some device designs, it may be desirable to mount multiple components in an array. For example, some electronic components benefit from operation as a coordinated group. It may be helpful in such arrangements to mount components in close proximity to each other. If care is not taken, components may be damaged during installation, damage may be created to the housing to which the components are being mounted, components may be difficult to repair when faults are detected, or components may consume more space within a device than desired. 
     It would be desirable to be able to address these challenges with a mounting scheme that is suitable for use when mounting components in a variety of housings. 
     SUMMARY 
     An electronic device may have a housing wall. An array of electrical components may be mounted in a corresponding array of openings in the housing wall. The components may be audio components, light-based components, sensors, or other electrical components. Gaskets may be used to seal the electrical components to the housing wall. 
     The housing wall may be planar or may be curved. Curved housing walls may have cylindrical shapes to form cylindrical housings. The array of openings in the housing may cover some or all of the surface of the cylindrical housing wall. Each electrical component may have a connector that is coupled to a signal path in the electrical device 
     The electrical components may be mounted to the housing wall using rotational motion in which each electrical component is rotated about a rotational axis. With this type of configuration, the electrical components may be provided with threads that engage mating threads on a component mounting structure or the electrical components may also have protrusions or other features that engage the inner surface of the housing wall as the electrical components are rotated. Each electrical component may, for example, be rotated by a quarter turn to mount the component within a housing opening as the protrusions or other features press against the inner housing wall surface. 
     Component mounting structures that receive the electrical components may be used in attaching the electrical components to the housing. Component cover structures with openings may overlap the components. Engagement features may help prevent relative rotational motion between the electrical components and the housing wall of the electronic device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device such as a laptop computer in accordance with an embodiment. 
         FIG. 2  is a perspective view of an illustrative electronic device such as a handheld electronic device in accordance with an embodiment. 
         FIG. 3  is a perspective view of an illustrative electronic device such as a tablet computer in accordance with an embodiment. 
         FIG. 4  is a perspective view of an illustrative electronic device such as a computer display in accordance with an embodiment. 
         FIG. 5  is perspective of an illustrative electronic device such as a computing device or other device with a cylindrical housing that surrounds an interior region and that is surrounded by an exterior region in accordance with an embodiment. 
         FIG. 6  is a cross-sectional side view of an illustrative electronic component being mounted in an opening in a device housing in accordance with an embodiment. 
         FIG. 7  is a cross-sectional side view of the illustrative electronic component of  FIG. 6  following mounting of the component to the device housing in accordance with an embodiment. 
         FIG. 8  is a cross-sectional side view of an electronic device showing how an array of components may be mounted to the exterior of a device housing in accordance with an embodiment. 
         FIG. 9  is a front view of an illustrative electronic component with a circular outline in accordance with an embodiment. 
         FIG. 10  is a front view of an illustrative electronic component with an oval outline in accordance with an embodiment. 
         FIG. 11  is a front view of an illustrative electronic component with a rectangular outline in accordance with an embodiment. 
         FIG. 12  is a front view of an illustrative electronic component with a hexagonal outline in accordance with an embodiment. 
         FIG. 13  is a cross-sectional side view of an illustrative electronic component with a trapezoidal cross section in accordance with an embodiment. 
         FIG. 14  is a cross-sectional side view of an illustrative electronic component with a smoothly tapered cross section in accordance with an embodiment. 
         FIG. 15  is a cross-sectional side view of an illustrative electronic component with a cross section that is tapered in a step-wise fashion in accordance with an embodiment. 
         FIG. 16  is a cross-sectional side view of an illustrative electronic component with a cross section that is triangular in shape and has untapered portions in accordance with an embodiment. 
         FIG. 17  is a top view of an illustrative component with a flat outer surface that has been mounted in an opening in a cylindrical housing in accordance with an embodiment. 
         FIG. 18  is a top view of an illustrative component with a curved outer surface that has been mounted in an opening in a cylindrical housing in accordance with an embodiment. 
         FIG. 19  is an exploded perspective view of an illustrative electronic device in which a component is being rotationally mounted in an opening in a housing with a curved surface such as a cylindrical housing in accordance with an embodiment. 
         FIG. 20  is a cross-sectional top view of a component mounted in a housing such as a cylindrical housing showing how a gasket may help form a seal between the component and the housing in accordance with an embodiment. 
         FIG. 21  is a cross-sectional top view of a component being rotationally mounted in a housing such as a cylindrical housing showing how a protrusion or other feature on the component may bear against an inner housing wall surface to draw the component against the housing as the component is rotated by a quarter turn in accordance with an embodiment. 
         FIG. 22  is a cross-sectional top view of an illustrative component that is being mounted in a housing such as a cylindrical housing using snaps that interlock with recesses in the housing in accordance with an embodiment. 
         FIG. 23  is a front view of an illustrative housing having recesses to release the snaps of the component of  FIG. 22  when the component is rotated in accordance with an embodiment. 
         FIG. 24  is a cross-sectional view of a portion of a housing such as a cylindrical housing having a guide structure that helps seat a component in an opening in the housing in accordance with an embodiment. 
         FIG. 25  is a cross-sectional view of a portion of a housing and component being joined using a slotted component retention member in accordance with an embodiment. 
         FIG. 26  is a front view of a slotted member of the type that may be used to join the component and housing of  FIG. 25  in accordance with an embodiment. 
         FIG. 27  is a perspective view of an illustrative component and an associated rotating locking ring that may be used in mounting the component to a housing in accordance with an embodiment. 
         FIG. 28  is a cross-sectional side view of an illustrative component with a rotating locking ring before the locking ring has locked the component into place in a housing in accordance with an embodiment. 
         FIG. 29  is a cross-sectional side view of the illustrative component of  FIG. 28  that has been mounted in a housing such as a cylindrical housing by rotation of the locking ring of  FIG. 28  against cam structures in accordance with an embodiment. 
         FIG. 30  is a front view of an illustrative housing opening with radially outward protruding portions in accordance with an embodiment. 
         FIG. 31  is a component mounting structure that can be used to mount a component in the housing opening of  FIG. 30  in a housing wall such as a cylindrical housing wall in accordance with an embodiment. 
         FIG. 32  is an exploded cross-sectional side view of an illustrative component and component mounting structure for mounting the component in a housing opening in accordance with an embodiment. 
         FIG. 33  is an exploded perspective view of an illustrative electrical component, cover structure, and housing having an opening to receive the component and cover structure in accordance with an embodiment. 
         FIG. 34  is a front view of a portion of a portion of a housing having an interlock feature that mates with a corresponding interlock feature on a component guard structure or other cover in accordance with an embodiment. 
         FIG. 35  is a front view of an illustrative component guard structure or other cover structure having an interlock feature that mates with the housing interlock feature of  FIG. 34  and that has interlock features that mate with component interlock features in accordance with an embodiment. 
         FIG. 36  is a front view of an illustrative component having component interlock features that mate with corresponding interlock features on the component guard structure of  FIG. 35  in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices may include components. The components may be light-based components, audio components, sensors, or other electrical components. The components may be mounted within the interior of an electronic device and/or may be mounted on the exterior of an electronic device. Configurations in which electrical components are exposed on the exterior of a housing may facilitate signal input and output operations using the components (e.g., input and output operations involving light signals, acoustic signals, temperature information, etc.). Accordingly, configurations in which components are mounted within openings in housing surfaces are sometimes described herein as an example. 
     In some devices, it may be desirable to mount multiple components in proximity to each other. For example, optical components may be mounted in proximity to each other to form a display with an array of pixels or other light output device (e.g., a light-based status indicator), speakers may be mounted in an array to form a phased speaker array or to provide enhanced output levels, microphones may be mounted in an array to gather audio information from multiple directions, proximity sensors may be mounted in an array to create a touch or motion input device that can capture input from a user&#39;s hand or other external object, and other sensors and input-output components may be mounted in arrays to enhance the ability of an electronic device to gather input and provide output. 
     Multiple components may be mounted adjacent to one another in a regular array having one or more rows and one or more columns of electrical components. Components may also be organized in a less regular fashion such as a pseudorandom pattern on the surface of a device housing. 
     Illustrative electronic devices that may be provided with components are shown in  FIGS. 1, 2, 3, 4, and 5 . 
     Illustrative electronic device  10  of  FIG. 1  has the shape of a laptop computer having upper housing  12 A and lower housing  12 B with components such as keyboard  16  and touchpad  18 . Device  10  may have hinge structures  20  that allow upper housing  12 A to rotate in directions  22  about rotational axis  24  relative to lower housing  12 B. Display  14  may be mounted in upper housing  12 A. Upper housing  12 A, which may sometimes be referred to as a display housing or lid, may be placed in a closed position by rotating upper housing  12 A towards lower housing  12 B about rotational axis  24 . 
       FIG. 2  shows how electronic device  10  may be a handheld device such as a cellular telephone, music player, gaming device, navigation unit, or other compact device. In this type of configuration for device  10 , housing  12  may have opposing front and rear surfaces. Display  14  may be mounted on a front face of housing  12 . Display  14  may, if desired, have openings for components such as button  26 . Openings may also be formed in display  14  to accommodate a speaker port (see, e.g., speaker port  28  of  FIG. 2 ). 
       FIG. 3  shows how electronic device  10  may be a tablet computer. In electronic device  10  of  FIG. 3 , housing  12  may have opposing planar front and rear surfaces. Display  14  may be mounted on the front surface of housing  12 . As shown in  FIG. 3 , display  14  may have an opening to accommodate button  26  (as an example). 
       FIG. 4  shows how electronic device  10  may be a computer display, a computer that has been integrated into a computer display, or a display for other electronic equipment. With this type of arrangement, housing  12  for device  10  may be mounted on a support structure such as stand  30  or stand  30  may be omitted (e.g., stand  30  can be omitted when mounting device  10  on a wall). Display  14  may be mounted on a front face of housing  12 . 
       FIG. 5  shows how electronic device  10  may have a cylindrical housing. Device  10  may be, for example, a desktop computer such as the Mac Pro computer available from Apple Inc. of Cupertino, Calif. Housing  12  may have an input-output connector region such as region  32  that contains input-output connectors (e.g., Universal Serial Bus connectors and other digital signal connectors, power connectors, audio connectors, memory card slots, and other input-output connectors). Upper surface  12 - 1  of housing  12  may be planar or may have curved surfaces (as shown in  FIG. 5 ). Sidewall  12 - 2  of housing  12  may have a curved surface so that housing  12  has a cylindrical shape (as an example). Housing  12  may also have other shapes (e.g., conical shapes, pyramidal shapes with curved and/or planar sidewall surfaces, spherical housing shapes, other shapes, and combinations of these shapes). 
     Housing  12  may have a vertical dimension (height in dimension Z) that is larger than its lateral (horizontal) dimensions (i.e., widths in dimensions X and Y). Configurations in which housing  12  is shorter in height and wider in width may also be used. If desired, part of housing  12  may be cylindrical and part of housing  12  may have one or more planar sidewalls. For example, housing  12  may have the shape of a half cylinder in which the front portion of housing  12  has a cylindrical shape and the rear portion of housing  12  has a planar rear housing wall. Other shapes with cylindrical surfaces may also be used (e.g., quarter cylinders, three-quarter cylinders, etc.). Display  14  may be mounted in housing  12  or may be omitted from device  10  of  FIG. 5 . 
     The illustrative configurations for device  10  that are shown in  FIGS. 1, 2, 3, 4, and 5  are merely illustrative. In general, electronic device  10  may be a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a media player, or other handheld or portable electronic device, a smaller device such as a wrist-watch device, a pendant device, a headphone or earpiece device, or other wearable or miniature device, a television, a computer display that does not contain an embedded computer, a gaming device, a navigation device, an embedded system such as a system in which electronic equipment with a display is mounted in a kiosk or automobile, an accessory such as a charging station, a stand for a display, speaker or other electronic device, an alarm clock, a speaker, a docking station, an amplifier, a projector, a camera, a video camera, gaming equipment, a television cable box or other set-top box, lighting equipment, a motion sensor, a touch pad or other input-output device that gathers data from a touch sensor(s), networked attached storage or other data storage device, a wireless access point, a router, or other network equipment, other equipment, or equipment that implements the functionality of two or more of these devices. 
     Housing  12  of device  10 , which is sometimes referred to as a case, may be formed of materials such as plastic, glass, ceramics, carbon-fiber composites and other fiber-based composites, metal (e.g., machined aluminum, stainless steel, or other metals), other materials, or a combination of these materials. Device  10  may be formed using a unibody construction in which most or all of housing  12  is formed from a single structural element (e.g., a piece of machined metal or a piece of molded plastic) or may be formed from multiple housing structures (e.g., outer housing structures that have been mounted to internal frame elements or other internal housing structures). 
     Display  14  may be a touch sensitive display that includes a touch sensor or may be insensitive to touch. Touch sensors for display  14  may be formed from an array of capacitive touch sensor electrodes, a resistive touch array, touch sensor structures based on acoustic touch, optical touch, or force-based touch technologies, or other suitable touch sensor components. 
     Display  14  may include display pixels formed from liquid crystal display (LCD) components, organic light-emitting diode pixels, or other suitable image pixel structures. If desired, display  14  may be omitted from device  10  (e.g., to conserve space) or multiple displays such as display  14  may be included in device  10  (e.g., in an array). Light-based status indicators and other input-output devices may be used to supplement information displayed on display  14  or may be used to provide a user with status information and other output when display  14  has been omitted. 
     If desired, one or more electrical components may be mounted on housing  12 . For example, a single component or an array of components may be mounted in the position(s) of illustrative component(s)  34  of  FIG. 5  or elsewhere on housing  12  of  FIG. 1, 2, 3, 4 , or  5  or on other electronic device housings. Electrical components  34  may be mounted on a planar housing wall or a curved housing wall. Components  34  may, for example, be mounted an a surface of housing  12  where housing  12  has a non-planar surface such as where housing wall  12 - 2  of  FIG. 5  is curved (e.g., curved on the side of a cylinder). In general, components  34  may be mounted on a curved surface such as a corner of a housing, a rounded edge of a housing, a curved sidewall, a curved front wall, a curved rear wall of housing  12 , a curved top wall, etc. Configurations in which housing  12  has a cylindrical surface on which components  34  are mounted in an array (e.g., configurations of the type shown in  FIG. 5  in which components  34  are mounted in an array on some or all of curved cylindrical outer surface  12 - 2  of housing  12 ) are sometimes described herein as an example. 
     The electrical components that are mounted to housing  12  such as components  34  of  FIG. 5  may be electrical components such as light-emitting diodes, lamps, displays, lasers, or other light-emitting components, may be vibrators, buzzers, speakers, tone-generators, microphones, or other acoustic components, may be sensors such as touch sensors, temperature sensors, accelerometers, compasses, gyroscopes, position sensors, proximity sensors, or may be other suitable electronic components. 
     As shown in  FIG. 6 , each component  34  may be mounted in a respective opening in housing wall  12 - 2  such as opening  36 . Component  34  may be mounted from the exterior of device  10  or from the interior of housing  12 . After component  34  has been placed within opening  36 , fasteners or other suitable attachment mechanisms (e.g., clips, adhesive, springs, other engagement features, etc.) may be used in securing component  34  to housing wall  12 - 2 . 
     As shown in  FIG. 7 , component  34  may be mounted so that some or all of exterior component surface  40  is flush (or nearly flush) with outer surface  38  of housing wall  12 - 2 . In configurations in which housing wall  12 - 2  is curved (e.g., when wall  12 - 2  forms part of a cylinder), external component surface  38  may have a matching curved surface (e.g., some or all of the curvature of surface  40  of component  34  may match (or nearly match) the curvature of housing wall surface  38 . 
     Electrical components  34  may be coupled to control circuitry using signal paths such as signal path  42  of  FIG. 7 . Signal path  42  may include one or more conductive lines on printed circuits or other substrates, wires, optical fibers, light-pipes, cables, plastic carriers with metal traces or other electrical signal lines, or other signal paths. The electrical and/or optical paths that are coupled to components  34  may be used to carry power signals, digital and/or analog signals (e.g., control signals, image data, audio signals, sensor information, etc.), or other signals. 
     Connectors such as connector  44  of  FIG. 7  may be used to facilitate attachment of the electrical components to signal path  42 . For example, components  34  may each have a respective connector such as connector  44  of  FIG. 7  that mates with a corresponding connector on an optical and/or electrical cable or other signal path  42 . Connector  44  may be a zero insertion force cable or other printed circuit connector, may be a coaxial connector or other rotationally symmetric connector for audio and/or radio-frequency signals, may be a power connector, may be a Universal Serial Bus connector or other digital data connector, may be an Ethernet connector, may be an audio connector, may be an optical connector, may be a male connector, may be a female connector, may be a locking connector, may be an reversible (orientation independent) connector with two or more operating positions, or may be any other suitable connector. If desired, connector  44  may have mating contacts that can be coupled and decoupled without using a fixed connection such as a solder or conductive adhesive connection Alternatively, connections between component  34  and a signal path may be made by using solder or conductive adhesive to join mating contacts (e.g., contacts on components  34  and mating contacts on a cable, printed circuit substrate, or other carrier with metal traces or other electrical signal lines). 
     Components such as component  34  of  FIG. 7  may contain subcomponents such as subcomponents  46  and  48 . Subcomponent  46  may be located near the front face of component  34  and may be a lens or lens system (e.g., when component  34  is an optical component), may be a diaphragm or speaker grill (e.g., when component  34  is a speaker), may be a microphone diaphragm, may be an optically or acoustically transparent window structure, may be a dielectric member (e.g., to form a window that allows electromagnetic signals for a sensor to pass through the window), may be a thermally conductive member that allows heat to pass into component  34 , or may be other suitable front-of-component subcomponent. Subcomponent  48  may be a light source such as a light-emitting diode, laser, or lamp, may be a light detector such as an image sensor or photodetector, may be a speaker driver (e.g., a driver that drives a diaphragm), may be a temperature sensor such as a solid state temperature sensor or a thermocouple, may be a motion sensor, capacitive sensor, or other type of sensor, or may be other suitable electrical subcomponent for supporting the operation of component  34 . 
     If desired, components  34  may be mounted in a continuous (or nearly continuous) array of rows and columns on the outer curved surface of cylindrical housing wall  12 - 2 , as shown in the illustrative cross-sectional side view of device  10  in  FIG. 8 . Components  34  may also be mounted on internal housing structures and/or walls such as upper wall  12 - 1 . An optional covering such as covering  50  may be used to cover components  34 . Covering  50  may be acoustically transparent (e.g., covering  50  may be a plastic mesh and/or metal mesh or other cover with openings to allow sound to pass), may be optically transparent (e.g., by using a transparent or semi-transparent material or pattern of material such as frosted glass, plastic with a thin semitransparent coating or patterned coating layer), may be sufficiently thermal conductive to allow temperature measurements to be made through covering  50  (e.g., a thin metal cover), or may be any other suitable covering structure for improving device aesthetics, enhancing component protection, etc. 
     There may be any suitable number of components  34  in the array of components on wall  12 - 2  (e.g., one or more, two or more, five or more, 10 or more, 20 or more, 50 or more 2-200, 5-150, 20-100, less than 100, less than 50, less than 300, less than 20, 20-70, 20-100, or other suitable number). The distance between adjacent components  34  may be less than 10 mm, 2-5 mm, less than 20 mm, more than 3 mm, between 1-15 mm, less than 5 mm, etc. 
     Components  34  may have any suitable shapes such as box shapes, frustoconical shapes (e.g., frustoconical shapes with planar and/or curved ends), pyramidal shapes, shapes with front surfaces that are wider than their opposing rear surfaces, shapes with curved edges and/or straight edges, shapes with curved front surfaces, etc.), cone shapes, step-wise varying cone shapes, spherical shapes, disk shapes, shapes with combinations of curved and straight edges and planar and/or curved sidewalls, etc.).  FIGS. 9, 10, 11, and 12  are front views of illustrative shapes that may be used for components  34 . In the example of  FIG. 9 , component  34  has a circular outline when viewed from the front (i.e., when viewed from the exterior of device  10  when component  34  has been mounted in housing sidewall  12 - 2 ). In the example of  FIG. 10 , component  34  has an oval outline when viewed from the front.  FIG. 11  shows how component  34  may have a rectangular outline when viewed from the front. In the illustrative configuration of  FIG. 12 , component  34  has a hexagonal shape when viewed from the front. Other shapes may be used for component  34  if desired. The examples of  FIGS. 9, 10, 11, and 12  are merely illustrative. 
     Cross-sectional side views of components  34  of different illustrative shapes are shown in  FIGS. 13, 14, 15, and 16 . As shown in  FIG. 13 , component  34  may have a front face such as front face  34 - 1 , an opposing rear face such as rear face  34 - 2 , and side surfaces such as surfaces  34 - 3 . Some or all of front face  34 - 1  may lie flush with outer surface  38  of housing  12 - 2  (i.e., front face  34 - 1  of component  34  may form exterior surface  40  of  FIG. 7 ). In the example of  FIG. 13 , front face  34 - 1  has larger lateral dimensions (in vertical dimension Z and horizontal dimension X) than rear face  34 - 2 . Side surfaces  34 - 3  form a tapering shape so that component  34  is wider at the front than at the rear. Side surfaces  34 - 3  are straight in the cross-sectional side view of  FIG. 13 . In the illustrative configuration of  FIG. 14 , side surfaces  34 - 3  have smoothly tapering curved profiles.  FIG. 15  shows how side surfaces  34 - 3  may progressively narrow component  34  in a step-wise fashion. In the example of  FIG. 16 , side surfaces  34 - 3  have portions in which component  34  does not taper and portions in which component  34  tapers. Connector  44  may be mounted on rear surface  34 - 2  of component  34  or elsewhere in component  34 . If desired, other side profiles may be used for component  34  (e.g., tapered and/or non-tapered profiles). The configurations of  FIGS. 13, 14, 15, and 16  are shown as examples. 
     It may be desirable to provide front face  34 - 1  of component  34  with a surface shape that matches the surface shape of housing wall  12 - 2 . For example, if housing wall  12 - 2  has a cylindrical shape with a curved (circular) outer surface, component  34  may have a matching curved outer surface.  FIG. 17  is a top view of an illustrative configuration in which component  34  has a front surface (surface  34 - 1 ) that is planar. As a result, surface  34 - 1  does not match the curvature of the curved outer surface of cylindrical housing wall  12 - 2 .  FIG. 18  shows how component  34  may be provided with a curved outer surface (surface  34 - 1 ) that matches the curved outer surface of cylindrical housing wall  12 - 2 . If desired, peripheral edges of surface  34 - 1  or other portion of surface  34 - 1  may match the curved surface of cylindrical housing wall  12 - 2  and other portions (e.g., central portion  34 - 1 ′) may have other surface shapes (e.g., protruding and/or recessed shapes, planar shapes, dome-shaped configurations, etc.). 
       FIG. 19  is an exploded perspective view of an illustrative rotationally mounted component. As shown in  FIG. 19 , housing wall  12 - 2  may have an opening such as opening  36  (e.g., a circular housing wall opening). Housing wall  12 - 2  may form part of a cylinder (i.e., wall  12 - 2  of  FIG. 19  may be curved), may be planar, or may have other suitable shapes. Component  34  may be installed within opening  36  by moving component  34  inwardly in direction  62  and then rotating component  34  in direction  64  about rotational axis  60 . Component  34  may have recesses  70  or other features around its periphery that engage with corresponding features (e.g., mating protrusions) on an installation tool to facilitate rotation of component  34  using the installation tool. The periphery of component  34  may be circular. 
     When component  34  is mounted in opening  36 , gasket  68  may be compressed between component  34  and housing wall  12 - 2  (see, e.g., ridge  66  in opening  36 ), thereby forming a circumferential seal around the edge of component  34 . When component  34  is inserted in opening  36 , protrusions such as protrusion  72  may engage the inner surface of housing wall  12 - 2 . During rotation of component  34 , these protrusions may bear against the inner surface of wall  12 - 2  and may pull component  34  inwardly in direction  62  due to the curved shape of the inner wall surface. 
     As shown in  FIG. 20 , housing wall ridge  66  and opposing portions of component  34  such as portion  74  may have angled surfaces that drive ring-shaped gasket  68  outwardly in direction  76  during movement of component  34  in direction  68 . This helps ensure that a satisfactory seal is formed between component  34  and housing  12 . 
       FIG. 21  is a cross-sectional view of component  34  showing how protrusions such as protrusion  72  may engage inner surface  78  of housing wall  12 - 2 . Initially, protrusion  72  may be located in position  82 . As component  34  is rotated about axis  60  (e.g., by rotating component  34  by a quarter turn or other suitable amount), protrusion  72  will move from position  82  to position  84  in direction  80 , riding along inner wall surface  78  of housing wall  12 - 2 . The curvature of inner wall surface  78  interacts with protrusion  72  to pull component  34  inwardly in direction  62  as component  34  rotates protrusion  72  in direction  80 . Component  34  may have a pair of protrusions  72  on opposing sides of component  34  or may have other numbers of protrusions  72 . 
     If desired, component  34  may be mounted in housing wall  12 - 2  using flexible prongs  86 . Prongs  86  may engage mating recesses such as groove(s)  88  in housing wall  12 - 2 , thereby pulling component  34  outwardly in direction  90 . Prongs  86  may be formed from metal or plastic and may be formed as portions of component  34  or as separate structures (e.g., structures that are attached to component  34 ). In configurations of the type shown in  FIGS. 19, 20, and 21 , component  34  may be mounted in housing wall  12 - 2  from the exterior of housing  12 . In configurations of the type shown in  FIG. 22 , component  34  may be mounted in housing  12 - 2  from the interior of housing  12 . As shown in  FIG. 22 , gasket  68  may be compressed between portions of component  34  and portions of housing wall  12 - 2 , thereby sealing component  34  in the opening of wall  12 - 2 . 
     It may be desirable to disengage prongs  86  to release component  34  from housing  12  (e.g., to repair component  34 ). With one suitable arrangement, opening  36  in housing  12  may be provided with radially enlarged portions such as portions  92 . When it is desired to mount component  34  in housing wall  12 - 2 , prongs  86  may be inserted into grooves  88  in housing wall  12 - 2 . When it is desired to remove component  34  from housing wall  12 - 2 , component  34  may be rotated so that prongs  86  move out of grooves  88  and into the space crated by radially outwardly enlarged portions  92 . This releases prongs  86  and allows component  34  to be removed from housing wall  12 - 2 . 
     It may be desirable to provide structures that help guide component  34  into opening  36  when installing component  34  in housing  12 . As shown in  FIG. 24 , for example, component  34  may be guided into opening  36  in housing wall  12 - 2  using guide structure  94 . Guide structure  94  may be a plastic or metal member with a planar portion that is attached to the inner surface of housing wall  12 - 2  using adhesive  96  and an angled portion that forms a guiding ramp that helps guide component  34  into a desired position in opening  36  without allowing component  34  to strike wall  12 - 2  and potentially be damaged by wall  12 - 2 . 
       FIG. 25  is a cross-sectional side view of an illustrative component that is being mounted in housing  12  using a retention member. Retention member  98  or other attachment structure may be formed from metal, plastic, or other materials and may be formed as an integral portion of component  34 , as a separate structure that is attached to component  34  using adhesive, screws or other fasteners, or other attachment mechanisms. When component  34  is moved into opening  36  in direction  90  from the interior of housing  12 , retention member  98  will flex so that the tip of retention member  98  rides up and over protrusion  100  on housing wall  12 - 2  until protrusion  100  is received within opening  102  of retention member  98 . There may be a series of protrusions  100  around the circular edge of opening  36  and a corresponding set of protruding retention member portions with openings  102  around the circular periphery of component  34 . The engagement between each protrusion  100  and each opening  102  helps to secure component  34  to housing wall  12 - 2  within opening  36 . 
       FIG. 26  shows how opening  102  may have the shape of an elongated slot in retention member  98 . Other types of engagement features (circular openings, prongs, etc.) may be used if desired. The use of slot-shaped openings and corresponding slot-shaped protrusions  100  on housing wall  12 - 2  to engage the slot-shaped openings is merely illustrative. Retention member  98  may have a ring portion that surrounds the circular periphery of component  34 . Tab-shaped portions such as the structure of  FIG. 26  may protrude from the ring portion (i.e., the retention member portions formed from the tabs on the ring may each engage a separate corresponding protrusion  100 ). 
     A perspective view of an illustrative component mounting structure based on a rotating locking ring is shown in  FIG. 27 . In the example of  FIG. 27 , locking ring  104  has a circular ring shape that surrounds component  34 . Prongs  106  protrude downward (in the orientation of  FIG. 27 ) along the edges of cam structure  110 . Outwardly protruding tabs  108  may be located at the ends of prongs  106 . Cam structure  110  may be formed from plastic, metal, or other suitable materials and may be formed as part of component  34  or a separate structure that is attached to component  34 . 
     To lock component  34  to housing  12 , component  34  and the locking ring structures of  FIG. 27  may be inserted in opening  36  of housing  12 . Ring  104  may then be rotated about rotational axis  60 . During rotation, the surfaces of cam structure  110  may cause ring  104  to engage with structures in housing  12 , thereby mounting component  34  to housing  12 . 
       FIG. 28  is a cross-sectional view of component  34  of  FIG. 27  in a configuration in which ring  104  has not yet been rotated to secure component  34  in housing  12 . Housing wall  12 - 2  or other portions of housing  12  may be provided with grooves such as groove  112  to receive corresponding tabs such as tab  108 . In a configuration of the type shown in  FIG. 28  in which locking ring  104  has not yet been rotated, the surfaces of cam structure  110  will not force tabs  108  outward and tabs  108  will not protrude into grooves  112 . 
     When it is desired to mount component  10  to housing  12 - 2 , rotating locking ring  104  may be rotated about rotational axis  60 . Portion  110  of component  34  forms a cam structure. The slope of the sidewall of the cam structure varies continuously as a function of rotational position around axis  60 . Initially, the outer cam surface against which prong  106  bears is inwardly sloped as shown in  FIG. 28 . Following rotation about axis  60 , locking ring prong  106  will be moved to a location in which outer wall surface  118  of cam portion  110  of component  34  has become more vertical, pushing prong  106  outward in direction  116 , as shown in  FIG. 29 . This pushes tab  108  at the end of prong  106  into engagement with groove  112  in housing wall  12 - 2 . At the same time, the thickness T of cam portion  110  increases from a first thickness when prong  106  is in the location of prong  106  in  FIG. 28  and a second thickness when prong  106  is in the location of prong  106  in  FIG. 29 . This increase in the thickness of the cam structure as tab  108  rotates along cam structure  110 , forces tab  108  upward in direction  114 . As tab  108  is pulled upward within groove  112 , portion  110  of component  34  is pulled outward towards the exterior of device  10  in direction  120 , thereby compressing gasket  68  between portion  110  and housing wall  12 - 2 . 
     If desired, components  34  may be mounted in openings in housing  12  using a configuration in which a cover or other structure screws into a component mounting structure with a mounting cavity. A component to be mounted in housing  12  may be mounted in opening  36  between a cover on the exterior of housing  12  that is screwed into a component mounted structure in the interior of housing  12 . The component mounting structure may have a dish shape or other shape with a mounting cavity that is configured to receive component  34 . The cover may be a structure with openings (e.g., a guard structure for a speaker diaphragm, a guard structure for a lens in a light-based component, etc.). 
     Consider, as an example, the illustrative shape for opening  36  in housing wall  12 - 2  (e.g., a cylindrical housing wall) that is shown in  FIG. 30 . Opening  36  may have a circular shape that is configured to receive a circular component. The component may have a circular periphery that fits through opening  36  of  FIG. 30  and may be mounted from the interior or exterior of housing  12 . Opening  36  may have radial protrusions  122  to facilitate removal of a component mounting structure from the interior of housing  12  for repair. Protrusions  122  may also facilitate insertion of a component mounting structure into the interior of housing  12  during component mounting. 
     An illustrative component mounting structure that may be used to secure a component in opening  36  of  FIG. 30  is shown in  FIG. 31 . Component mounting structure  126  may have a recessed portion forming a cavity such as cavity  132  into which component  34  may be received when mounting component to housing  12 . Component mounting structure  126  may be, for example, a dish-shaped plastic cap. Protrusions  124  of component mounting structure  126  may be large enough to cover protrusions  122  in housing opening  36 . When it is desired to remove component mounting structure  126  from the interior of housing  12 , component mounting structure  126  may be rotated sideways so that protrusions  124  can slide through protrusions  122  in opening  36  (as an example). Component mounting structure  126  may be mounted to the interior surface of housing wall  12 - 2  using adhesive, screws, or other suitable attachment mechanisms. A cover may be attached to housing  12  and/or component mounting structure  126  using screw threads, using screws, using adhesive, using snaps, or using other attachment mechanisms. 
     An exploded cross-sectional side view of optional component cover  136 , component  34 , housing wall  12 - 2 , and component mounting structure  126  (taken along line  128  and viewed in direction  130 ) is shown in  FIG. 32 . As shown in  FIG. 32 , component mounting structure  126  may have a curved rear surface and an interior such as cavity  132  that is configured to receive component  34 . Component mounting structure  126  may be mounted to the interior of housing wall  12 - 2  using adhesive  134  or other attachment mechanisms (screws, snaps, etc.). Component  34  and component mounting structure  126  may have mating threads that allow component  34  to be secured to component mounting structure  126  by screwing component  34  into component mounting structure  126  (i.e., by rotating component  34  about axis  60 ). Component  34  may also be mounted using adhesive, screws, or other attachment mechanisms. When component  34  is secured in place, component mounting structure will be pulled against the interior surface of wall  12 - 2  and will form a seal with housing wall  12 - 2 . 
     Optional component cover  136  may be press fit within opening  36 , may be attached to component  34  or housing wall  12 - 2  using adhesive  138 , may be screwed into threads on component  34  and/or housing wall  12 - 2 , or may be otherwise attached to device  10 . Component cover  136  may have openings to permit the passage of sound and/or light. For example, component cover structure  136  may have crossed members that serve as a guard structure for component  34  without blocking sound and light. 
       FIG. 33  is an exploded perspective view of an illustrative electrical component, component cover, and housing having an opening to receive the component and cover structure. Component  34  of  FIG. 33  may, if desired, be mounted in opening  36  of housing wall  12 - 2  using a quarter-turn mounting arrangement of the type described in connection with  FIGS. 19, 20 , and  21 . Component cover  136  of  FIG. 33  may be mounted over the front face of component  34  using a ring of adhesive  138 . Component cover  136  (e.g., cover  136  of  FIG. 32  and other device arrangements) may be formed from a mesh, crossed members, or other structure that has openings to permit sound and/or light to pass between component  34  and the surroundings of device  10 . 
       FIG. 34  is a front view of a portion of a housing having an interlock feature that mates with a corresponding interlock feature on a component cover structure (component guard). As shown in  FIG. 34 , opening  36  may have one or more radially extending portions such as groove  140  of  FIG. 34 . There may be, for example, a pair of grooves  140  on opposing sides of opening  36  or may be a single groove  140  on the periphery of opening  36 . Other configurations (e.g., configurations in which there are more than two grooves  140 ) may also be used. Each groove  140  serves as an alignment and locking feature to rotationally position component cover  136  relative to housing  12 . 
     Component cover  136  may have one or more alignment features such as illustrative alignment feature  142 . Feature  142  may be, for example, a protrusion that mates with groove  140  of  FIG. 34 . Cover structure  136  may also have one or more alignment features such as tabs  144  or other features (protrusions, recesses, etc.) that are configured to mate with corresponding alignment features on the outer face of component  34 . As shown in  FIG. 36 , for example, component  34  may have a series of notches  146  that run around the periphery of component  34 . When component  34  is installed within opening  36 , there is a potential for rotational movement between component  34  and housing wall  12 - 2 . Cover  136  can be installed over component  34  so that feature  142  interlocks with feature  140  on housing  12 - 2 , thereby locking cover  136  to housing  12 - 2  and preventing rotational movement of cover  136  with respect to housing wall  12 - 2 . At the same time, features  144  on cover  136  may engage features  146  on component  34 , thereby preventing component  34  from rotating relative to cover  136 . Because relative rotational movement between cover  136  and housing  12 - 2  is prevented by the engagement between features  140  and  142  and because relative rotational movement between cover  136  and component  34  is prevented by the engagement between features  144  and features  146 , rotational movement of component  34  relative to housing wall  12 - 2  is prevented. 
     The foregoing is merely illustrative and various modifications can be made by those skilled in the art without departing from the scope and spirit of the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20150522
Publication Date: 20170808
Grant Date: 20170808
Priority Date: 20140930
Inventors: HOBSON PHILLIP MICHAEL
BOSSCHER NATHAN P.
BAKER JOHN J.
STANLEY CRAIG M.
BOOZER BRAD G.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K5/0247", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 59410803