PATENT DOCUMENT

Publication Number: US-7510405-B1
Application Number: US-86188607-A
Country: US
Kind Code: B1

Title: Method of manufacturing an electronic device with a unitary outer body

Abstract:
Various embodiments of the present invention provide for methods of manufacturing an electronic device that utilizes a unitary outer body. In one embodiment, a method is provided for installing an exterior component into an interior chamber of the unitary outer body through an opening in the outer body. The exterior component may be sized such that it cannot fit into an open end of the outer body when it is coupled with an interior component. As the unitary outer body cannot be disassembled to receive the coupled components into its interior, a method of the present invention inserts an end of the exterior component into the unitary outer body through an opening provided in the outer body to couple with the interior component.

Claims:
1. A method of manufacturing a docking station for an electronic device, the method comprising:
 providing a unitary outer body that includes an interior chamber in communication with an open end of the body and an opening in a surface of the body; 
 providing an exterior electronic component and an interior electronic component, wherein the exterior component is physically dimensioned such that the exterior component cannot pass into the chamber when coupled with the interior component, and wherein the interior and exterior electronic components are configured to be fixed together for operation in the docking station; 
 positioning the interior component into the interior chamber through the open end to align an interface of the interior component with the opening; 
 moving an end of the exterior component into the chamber through the opening; and 
 coupling the end of the exterior component with the interface of the interior component such that the interior and exterior components are fixed together and capable of operating together in the docking station; 
 wherein providing a unitary outer body comprises providing a body formed of a single, continuous piece of material. 
 
   
   
     2. The method of  claim 1  wherein the unitary outer body is not formed from constituent parts. 
   
   
     3. The method of  claim 1  wherein providing a unitary outer body comprises forming the unitary outer body using one of an extrusion, molding, or milling process. 
   
   
     4. The method of  claim 1  wherein providing a unitary outer body comprises providing a body formed of plastic, metal, or ceramic material. 
   
   
     5. The method of  claim 1  wherein providing a unitary outer body comprises providing a body with two open ends in communication with the chamber. 
   
   
     6. The method of  claim 1  wherein providing an exterior component comprises providing a male 30-pin connector. 
   
   
     7. The method of  claim 1  wherein providing an interior component comprises providing a printed circuit board. 
   
   
     8. The method of  claim 1  wherein coupling the end of the exterior component with the interface of the interior component comprises inserting a board interface end of a male 30-pin connector into a spring loaded interface disposed on a printed circuit board. 
   
   
     9. The method of  claim 1  wherein coupling the end of the exterior component with the interface of the interior component comprises electrically coupling the exterior component with the interior component. 
   
   
     10. A docking station for an electronic device, comprising:
 a unitary outer body that includes an interior chamber in communication with an open end of the body and an opening in a surface of the body; 
 a circuit board disposed within the interior chamber; and 
 a connector including a device interface end configured to couple with the electronic device and a board interface end fixed to the circuit board, wherein the connector is physically dimensioned such that the connector cannot pass into the interior chamber when coupled with the circuit board, 
 wherein the circuit board is disposed within the interior chamber such that an interface of the circuit board is aligned with the opening in the body, and 
 wherein the device interface of the connector protrudes from the interior chamber through the opening for coupling with the electronic device; 
 wherein the unitary outer body is formed of a single, continuous piece of material. 
 
   
   
     11. The docking station of  claim 10  wherein the unitary outer body is not formed from constituent parts. 
   
   
     12. The docking station of  claim 10  wherein the unitary outer body is formed using one of an extrusion, molding, or milling process. 
   
   
     13. The docking station of  claim 10  wherein the unitary outer body comprises plastic, metal, or ceramic material. 
   
   
     14. The docking station of  claim 10  wherein the unitary outer body comprises two open ends in communication with the chamber. 
   
   
     15. The docking station of  claim 10  wherein the connector comprises a male 30-pin connector. 
   
   
     16. The docking station of  claim 10  where the device interface end is configured to couple with a media player. 
   
   
     17. The docking station of  claim 10  wherein the device interface end is configured to transmit power and data to the electronic device. 
   
   
     18. The docking station of  claim 10  wherein the interface comprises a spring loaded interface.

Description:
FIELD OF INVENTION 
   The present invention generally relates to a method of manufacturing electronic devices and the resulting product of said method. 
   BACKGROUND 
   Personal electronic devices, such as portable media players, cellular phones, personal digital assists, are prevalent in today&#39;s marketplace, as are the peripheral electronic devices that support their use, such as docking stations and the like. As competition in the personal electronics marketplace has grown, consumers have become more demanding in terms of both the performance and design aesthetic of such devices. For example, consumers expect ever smaller electronic devices that are more convenient to carry, and also look for product exteriors that are both functional and visually appealing. An exterior body design that has gained popularity, especially in smaller form factor electronic devices, is a single-piece unitary outer body. The unitary outer body design is contrasted with more conventional designs that, for example, create a device&#39;s outer body from two halves that are secured together with fasteners. 
   In a unitary outer body design, a single continuous piece of material, one that is not assembled from constituent parts, is used to create the outer body of the device. This unitary outer body is provided with a hollow interior chamber to house the device&#39;s electronic components. The use of a unitary outer body reduces or eliminates the need for fasteners such as screws and pins, which reduces both the cost of production and eliminates the sometimes unsightly appearance of fasteners on the product exterior. The unitary body also eliminates gaps or fissures on the product body where body components are joined. This provides a more robust and weatherproof outer body and improves the appearance of the product. Moreover, the elimination of multiple components in the outer body of a product makes the outer body more durable, as it also eliminates the possibility that the components will come apart with wear or trauma. 
   Given the advantages of unitary outer body design, it is desirable to solve specific problems that arise in the manufacture of an electronic device utilizing a unitary outer body. 
   BRIEF SUMMARY 
   One embodiment of the invention is directed to a method of manufacturing an electronic device comprising a unitary outer body. A unitary outer body is provided that includes an interior chamber in communication with an open end of the body and an opening in a surface of the body. An exterior electronic component and an interior electronic component are provided. The exterior component is physically dimensioned such that the exterior component cannot pass into the chamber when it is coupled with the interior component. The interior component is positioned in the interior chamber through the open end to align an interface of the interior component with the opening. An end of the exterior component is moved into chamber through the opening and coupled with the interface of the interior component. 
   Another embodiment of the invention is directed to an electronic device having a unitary outer body manufactured in accordance with the methods of the invention. 
   These and other embodiments of the invention are described in further detail below. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  shows a conceptual cross-sectional view of an electronic device in accordance with an embodiment of the present invention. 
       FIGS. 2A and 2B  show an exemplary docking station in accordance with an embodiment of the present invention. 
       FIG. 3  is a flow diagram illustrating a method in accordance with the present invention. 
   

   DETAILED DESCRIPTION 
   Embodiments of the invention provide a method for manufacturing an electronic device that utilizes a unitary outer body. In particular, a method is provided for installing an exterior component into an interior chamber of the outer body through an opening in the outer body. The exterior component may be sized such that the exterior component is unable to pass into an open end of the outer body when it is coupled with an interior component. For example, the exterior component may be a connector configured to protrude from an interior circuit board when the two are coupled together in the final installation. The connector may be taller, however, than a height of the open end of the unitary outer body. As the unitary outer body cannot be disassembled to receive such a component within its interior chamber, a method of the present invention may insert an interior electronic component (e.g., the circuit board) into the chamber of the unitary outer body such that a receiving interface of the interior component is aligned with an opening provided in the outer body. An end of the exterior component may then be introduced into the chamber through the opening and secured with the receiving interface to complete the installation. 
   As used herein, a unitary body is formed of a single, continuous piece of material that is not assembled from constituent parts. For example, the unitary body may be formed by an extrusion process that creates a continuous hollow body with two open ends. The unitary body may also be formed using other processes, such as by a molding process or a milling process to create a hollow body with only a single open end. The unitary body may be formed from plastic, metal, ceramic or any other suitable materials commonly used to house electronic components. 
     FIG. 1  shows a cross-sectional view of an electronic device that illustrates an embodiment of the present invention. In particular, electronic device  100  may include unitary outer body  10 . Outer body  10  may include hollow interior chamber  20  for housing electronic components of device  100 . Outer body  10  may also include opening  12  in a surface of the body, which allows components to pass into chamber  20  from the exterior of body  10 . As seen in cross-section, interior chamber  20  has dimension D 1  in direction  1 . Body  10  may include open end  14  in communication with chamber  20  that can be used to insert electronic components into chamber  20 . For example, as shown in  FIG. 1 , interior electronic component  30  may be disposed within chamber  20  via open end  14 . 
   Exterior electronic component  40  may be configured for installation in direction  1  for coupling with interior component  30  disposed within chamber  20 . Therefore, direction  1  can also be understood as the direction of installation of component  40 . Exterior component  40  has dimension D 2  in direction  1 . Component  40  may be configured such that end  42  can be used to couple with another electronic device (not shown) while end  44  can be used to couple with interior component  30  at interface  32 . 
   In instances where dimension D 2  of exterior component  40  is greater than or substantially equal to dimension D 1  of chamber  20 , it may become difficult or impossible for a manufacturer of electronic device  100  to couple exterior component  40  with interior component  30  and then introduce the coupled components into chamber  20  through open end  14 . Therefore, in accordance with an embodiment of the present invention, the device  100  may be manufactured by first disposing interior component  30  within chamber  20  such that interface  32  is aligned with opening  12 . End  44  of component  40 , which is configured to couple with interface  32 , may then be inserted through opening  12  into chamber  20  and coupled with interface  32  to complete the manufacture of device  100 . Once installed, exterior component  40  may be mechanically secured to and electrically coupled with interior component  30 . A portion of exterior component  40  adjacent end  42  may protrude from outer body  10  in the installed state. Moreover, exterior component  40  may enable interior component  30  to communicate with another electronic device coupled with end  42  of component  40 . 
     FIGS. 2A and 2B  illustrate an embodiment of the present invention as applied to a docking station for a portable electronic device such as an iPod. As shown in  FIG. 2A , docking station  200  may include a unitary outer body  210  that has interior chamber  220  for housing the electronic components of docking station  210 . For example, printed circuit board (PCB)  230  may be configured to be disposed within chamber  220 . PCB  230  may include interface  232  which may be configured to receive board interface end  244  of male 30-pin connector  240 . Device interface end  242  of connector  240  may be configured to mate with a female 30-pin connector (not show), as is provided in an iPod media player, to provide both data and power transfer. The connection between end  244  and interface  232  may be configured as a board-to-board style connection and/or may be configured with spring contacts. Any other type of suitable electrical connection may also be used to electrically couple connector  240  with PCB  230 . The connection may be configured to withstand significant lateral forces applied to end  242  of connector  240 . 
   Outer body  210  may include open end  214  that enables a manufacturer to insert PCB  230  into chamber  220 . Opening  212  may also be provided on outer body  210  to enable access from the exterior to chamber  220 . In the context of docking station  200 , it is desirable that a portion of male 30-pin connector  240  adjacent device interface end  242  protrudes from body  210  so as to enable the protruding portion to be inserted into and coupled with a female 30-pin connector (not shown). Therefore, docking station  200  may be configured with height H 2  of connector  240  being greater than height H 1  of outer body  210 . This spatial configuration renders it impossible to manufacture docking station  200  (with unitary body  210 ) by inserting connector  240  and PCB  230  in a coupled state into chamber  220 . Rather, docking station  200  may be manufactured by first inserting PCB  230  into chamber  220  via open end  214  such that interface  232  is aligned with opening  212 . Board interface end  244  of connector  240  may then be inserted through opening  212  into chamber  220  and coupled with aligned interface  232 . 
   As shown in  FIG. 2B , the installed connector  240  may be securely coupled with interface  232  disposed on PCB  230 . A portion of connector  240  may protrude from body  210  so as to enable device interface end  242  to be mated with a female 30-pin connector (not shown). As shown in  FIGS. 2A and 2B , screw hole  216  may be provided in body  210  and screw  250  may be installed to secure the connection between board interface end  244 , interface  232 , and outer body  210 . 
     FIG. 3  is a flow chart illustrating a method for manufacturing an electronic device that includes a unitary outer body, an interior electronic component, and an exterior electronic component in accordance with an embodiment of the present invention. At a first step  310 , a unitary outer body may be provided that includes an interior chamber in communication with an open end and an opening configured to allow a portion of the exterior electronic component to pass into an interior chamber. For example, with reference to  FIG. 2A , unitary body  210  may be provided having interior chamber  220  in communication with open end  214  and an opening  212  configured to allow an end of connector  240  to enter chamber  220 . At step  320 , an interior electronic component may be positioned into the interior chamber through the open end of the body such that an interface of the interior component is aligned with the opening in the body. For example, with continued reference to  FIG. 2A , PCB  230  may be inserted into chamber  220  through open end  214  such that interface  232  is aligned with opening  212 . 
   At step  330 , an end of an exterior electronic component is moved into the interior chamber through the opening in the outer body. For example, board interface end  244  of connector  240  may be moved into chamber  220  through opening  212 . The exterior component may be sized such that, when coupled with the interior component, the combination cannot be passed into the interior chamber of the body. For example, connector  240  may have height H 2  such that, when coupled with PCB  230 , the coupled components cannot pass into open end  214  having height H 1 . At step  340 , the inserted end of the exterior component is coupled with the interface of the interior component. For example, board interface end  244  of connector  240  is coupled with interface  232  so as to electrically couple PCB  230  with connector  240 . 
   It should be apparent to one skilled in the art that various changes and modifications can be made to this disclosure, and equivalents employed, without departing from the spirit and scope of the invention. Elements shown with any embodiment are exemplary for the specific embodiment and can be used on other embodiments within this disclosure. The above embodiments are provided for the purpose of illustration and not of limitation. The present invention is only limited by the following claims.

Metadata:
Filing Date: 20070926
Publication Date: 20090331
Grant Date: 20090331
Priority Date: 20070926
Inventors: PREST CHRIS
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T29/49002", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49002", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1632", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1632", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 40470154