PATENT DOCUMENT

Publication Number: US-8999487-B2
Application Number: US-201213607538-A
Country: US
Kind Code: B2

Title: Systems and methods for protection of cosmetic surfaces and overflow prevention on electronic devices

Abstract:
Systems and methods for protection of cosmetic surfaces on electronic devices and adhesive overflow prevention are provided. In particular, an assembly for protecting a cosmetic surface can include a heat activated adhesive, such as a heat active film adhesive (“HAF”), which can be used to secure a mesh to the cosmetic surface. In some embodiments, a protective layer having a center layer laminated between two layers of heat activated adhesive can be used to protect the cosmetic surface from scratches caused by the mesh. In some embodiments, one or more hot shoes can be used to cross-link the heat activated adhesives to the mesh and the cosmetic surface. Because the shape of a shoe can influence the flow of heat activated adhesives during cross-linking, different shoes can be selected in order to minimize overflow in certain locations in the assembly.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 glass with ink on a first side of the glass, the glass comprising a through-hole; 
 an adhesive layer having first and second sides, a protective layer between the first and second sides, and a cutout aligned with the through-hole; and 
 a mesh secured to the first side of the glass to cover the through-hole, wherein the first and second sides of the adhesive layer comprise cross-linked heat activated adhesive that, on the first side, secures the adhesive layer to the first side of the glass, and on the second side, secures the adhesive layer to the mesh. 
 
     
     
       2. The electronic device of  claim 1 , wherein the cross-linked heat activated adhesive is a heat active film adhesive (“HAF”). 
     
     
       3. The electronic device of  claim 1 , wherein the protective layer comprises a porous material. 
     
     
       4. The electronic device of  claim 1 , wherein the protective layer comprises at least one of a non-woven paper material having a higher melting temperature than the cross-linked heat activated adhesive, a plastic material, a fabric of glass, a fabric of natural fibers, and a metal foil. 
     
     
       5. The electronic device of  claim 4 , wherein the plastic material comprises at least one of a polyethylene terephthalate (“PET”) and polyimide (“PI”). 
     
     
       6. The electronic device of  claim 4 , wherein the metal foil is micro-perforated. 
     
     
       7. The electronic device of  claim 6 , wherein the metal foil is micro-perforated using at least one of die-cutting, laser cutting, and chemical etching. 
     
     
       8. The electronic device of  claim 1 , wherein the mesh is a woven metal weave comprising a plurality of sharp edges, and wherein the protective layer prevents the plurality of sharp edges of the mesh from scratching the ink on the glass. 
     
     
       9. The electronic device of  claim 1 , wherein the mesh is a matte textured mesh. 
     
     
       10. An electronic device, comprising:
 a glass layer having at least one opening; 
 a mesh attached to an interior surface of the glass layer, wherein the mesh covers the at least one opening in the glass layer; and 
 a heat activated thermoset adhesive interposed between the glass layer and the mesh that attaches the mesh to the interior surface, wherein the heat activated thermoset adhesive has a hole that that aligns with the at least one opening. 
 
     
     
       11. The electronic device defined in  claim 10  wherein the heat activated thermoset adhesive comprises first and second layers of heat activated thermoset film and a protective layer interposed between the first and second layers of heat activated thermoset film. 
     
     
       12. The electronic device defined in  claim 11  wherein the protective layer comprises plastic. 
     
     
       13. The electronic device defined in  claim 11  wherein the protective layer comprises metal foil. 
     
     
       14. The electronic device defined in  claim 11  wherein the protective layer comprises perforations and wherein the first and second layers of heat activated thermoset film are in contact with each other through the perforations. 
     
     
       15. The electronic device defined in  claim 11  further comprising a layer of ink formed on the interior surface of the glass layer, wherein the protective layer prevents the mesh from contacting the layer of ink. 
     
     
       16. The electronic device defined in  claim 11  wherein the first layer of heat activated thermoset film is attached to the interior surface of the glass layer, wherein the second layer of heat activated film is attached to the mesh, and wherein the second layer of heat activated thermoset film is thicker than the first layer of heat activated thermoset film. 
     
     
       17. The electronic device defined in  claim 10  further comprising:
 a layer of ink formed on the interior surface of the glass layer; and 
 a layer of hard-coat formed over the layer of ink, wherein the layer of hard-coat forms a barrier between the heat activated thermoset adhesive and the layer of ink. 
 
     
     
       18. The electronic device defined in  claim 10  wherein the at least one opening forms an acoustic opening.

Description:
FIELD OF THE INVENTION 
     This can relate to systems and methods for protection of cosmetic surfaces on electronic devices and, more particularly, to the protection of cosmetic surfaces during adhesive application. 
     BACKGROUND OF THE DISCLOSURE 
     Many electronic devices (e.g., media players and cellular telephones) often include one or more cosmetic surfaces. One example of a cosmetic surface is an area surrounding an acoustic opening, which can be made of glass. In some cases, a cosmetic mesh may be attached to the cosmetic surface. An adhesive, typically a pressure sensitive adhesive (“PSA”), may be used to attach the mesh to the cosmetic surface. 
     In particular, the PSA can be positioned in an indented location between the mesh and the cosmetic surface. Then, in order to activate the PSA, pressure can be applied to the PSA. Once the PSA sets after a period of time, the mesh can become attached to the cosmetic surface. 
     PSAs, however, are susceptible to the rotation and shift of the mesh after installation. Moreover, PSAs have relatively weak bonding strengths as compared to other adhesives. 
     SUMMARY OF THE DISCLOSURE 
     Systems and methods are disclosed for the protection of cosmetic surfaces on electronic devices and adhesive overflow prevention. As used herein, a “cosmetic surface” can refer to any surface of an electronic device that is prone to scratches such as, for example, an area surrounding an acoustic opening. In some cases, the cosmetic surface can be ink-covered glass. 
     A cosmetic surface assembly for protecting a cosmetic surface can include a heat activated adhesive, such as a heat active film adhesive (“HAF”), which can be used to secure a mesh to a cosmetic surface. In some embodiments, a protective layer having a center layer laminated between two layers of heat activated adhesive can be used to protect the cosmetic surface from scratches caused by the mesh. In particular, the protective layer can have a first side that secures the protective layer to the cosmetic surface. The protective layer can have a second side that secures the protective layer to the mesh. 
     In some embodiments, the protective layer can be made in laminated rolls before die-cutting. In these embodiments, a first cross-linking process can be used to secure the heat activated adhesives to the protective layer. At a later time, a second cross-linking process can be used to secure the protective layer to the mesh and the cosmetic surface. 
     In some embodiments, one or more hot shoes can be used to cross-link the heat activated adhesives to the mesh and the cosmetic surface. Because the shape of a shoe can influence the flow of heat activated adhesives during cross-linking, different shoes can be selected in order to minimize overflow in certain locations in the assembly. 
     In other embodiments, a layer of hard-coat can be used to prevent scratches from forming on the cosmetic surface. For example, the hard-coat can be added between the cosmetic surface (e.g., the ink on glass) and the heat activated adhesive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects of the invention, its nature, and various features will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1  is a perspective view of a mesh with pressure points; 
         FIG. 2  is a cross-sectional view of the mesh of  FIG. 1 ; 
         FIG. 3  is a cross-sectional view of a cosmetic surface assembly on an electronic device in accordance with some embodiments of the invention; 
         FIG. 4  is a close-up of portion A of the cross-sectional view of  FIG. 3  in accordance with some embodiments of the invention; 
         FIG. 5A  is a cross-sectional view of the assembly of  FIG. 3 , after a first step in a creation process, in accordance with some embodiments of the invention; 
         FIG. 5B  is a cross-sectional view of the assembly of  FIG. 5A , after a second step in the creation process, in accordance with some embodiments of the invention; 
         FIG. 5C  is a cross-sectional view of the assembly of  FIGS. 5A and 5B , after a third step in the creation process, in accordance with some embodiments of the invention; 
         FIG. 5D  is a cross-sectional view of the assembly of  FIG. 5A-5C , after a fourth step in the creation process, in accordance with some embodiments of the invention; 
         FIG. 5E  is a cross-sectional view of the assembly of  FIG. 5A-5D , after a fifth step in the creation process, in accordance with some embodiments of the invention; 
         FIG. 6A  is a cross-sectional view of another cosmetic surface assembly on an electronic device, after a first step in a creation process, in accordance with some embodiments of the invention; 
         FIG. 6B  is a cross-sectional view of the assembly of  FIG. 6A , after a second step in the creation process, in accordance with some embodiments of the invention; 
         FIG. 6C  is a cross-sectional view of the assembly of  FIGS. 6A and 6B , after a third step in the creation process, in accordance with some embodiments of the invention; 
         FIG. 6D  is a cross-sectional view of the assembly of  FIG. 6A-6C , after a fourth step in the creation process, in accordance with some embodiments of the invention; 
         FIG. 6E  is a cross-sectional view of the assembly of  FIG. 6A-6D , after a fifth step in the creation process, in accordance with some embodiments of the invention; 
         FIGS. 7A-7C  are perspective views of the successive application of different hot shoes to a cosmetic surface assembly in accordance with some embodiments of the invention; 
         FIG. 8  is a cross-sectional view of one approach for applying pressure to a cosmetic surface assembly in accordance with some embodiments of the invention; 
         FIG. 9  is a cross-sectional view of another approach for applying pressure to a cosmetic surface assembly in accordance with some embodiments of the invention; 
         FIG. 10  is a flowchart of an illustrative manufacturing process for creating an assembly for protecting cosmetic surfaces in accordance with some embodiments of the invention; and 
         FIG. 11  is a flowchart of another illustrative manufacturing process for creating an assembly for protecting cosmetic surfaces in accordance with some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Systems and methods for protection of cosmetics surfaces on electronic devices are provided and described with reference to  FIGS. 1-8 . 
       FIGS. 1 and 2  show perspective and cross-sectional views of a mesh  102 , respectively. Mesh  102  can be attached to one or more cosmetic surfaces of an electronic device. 
     As used herein, “cosmetic surfaces” can include any surface of an electronic device that may be prone to scratches (e.g., glass) such as, for example, a region of glass near an acoustic opening on an electronic device. In some embodiments, the cosmetic surface can include ink on one or more sides (e.g., ink-covered glass). 
     Mesh  102  can be created from a woven metal weave (e.g., a weave of wires). The woven metal weave can be subjected through a calendaring process to produce a matte textured mesh. The textured mesh can then be rotated by 45 degrees and cut to size (e.g., along line  104  of  FIG. 1 ). As shown in  FIG. 1 , the cutting of the mesh at a 45 degree angle can cause multiple sharp edges  106  to form on the mesh. As a result, when mesh  102  is later attached to a cosmetic surface, sharp edges  106  can scratch and damage the cosmetic surface. It is understood that mesh  102  can be made from non-metal materials such as, for example, aramid fibers. 
     In some embodiments, in order to prevent sharp edges  106  from scratching a cosmetic surface, mesh  102  can be subjected to a process to smooth these edges. For example, mesh  102  can be deburred such that sharp edges  106  can be turned away from the cosmetic surface. Persons skilled in the art will appreciate that any suitable process can be used to smooth sharp edges  106  including, for example, electro-polishing mesh  102 , applying a physical vapor deposition (“PVD”) coat to mesh  102 , electro-plating mesh  102 , and/or any combination thereof. 
     In addition to sharp edges  106 , the shape of mesh  102  can also damage cosmetic surfaces. In particular, because mesh  102  is formed from interleaved wires, multiple pressure points  202  ( FIG. 2 ) can exist on mesh  102 . Thus, similar to sharp edges  106 , pressure points  202  can also scratch a cosmetic surface when mesh  102  is attached. 
     In some embodiments, mesh  102  can be secured to a cosmetic surface using an adhesive. Conventionally, a pressure sensitive adhesive (“PSA”) can be used as the adhesive. Unfortunately, PSAs are susceptible to the rotation and shift of mesh  102  after mesh  102  is attached to the cosmetic surface. Moreover, PSAs have relatively weak bonding strengths as compared to other adhesives. 
     Thus, instead of PSAs, a heat activated film adhesive (“HAF”) can be used to secure mesh  102  to a cosmetic surface. HAF is a thermoset, which can be a heat-activated resin (e.g., phenolic resin) in its initial form. Following a cross-linking process, during which heat and pressure are jointly applied to the heat-activated resin, the HAF can be set to its final adhesive form. 
     In one embodiment, the HAF used to secure mesh  102  to the cosmetic surface can have a thickness of 0.08 mm. Persons skilled in the art will appreciate that this thickness is merely illustrative, and that any suitable thickness can be selected for the HAF. 
     Because setting a HAF requires the application of both heat and pressure, HAFs are more difficult to set as compared to PSAs, which require only pressure. In addition, HAF is a one-time heat set adhesive. In other words, once a HAF sets, the HAF can no longer be reflowed. 
     Despite these drawbacks, HAFs have multiple advantages over PSAs including: higher bonding strengths, better height control, and no possibility of mesh rotation or shift after installation. However, although HAF does not have a carrier, the use of a HAF as an adhesive can cause scratches on the cosmetic surface for other reasons. In particular, when attaching mesh  102  to ink-covered glass using a HAF, the HAF can soften when it is heated during the cross-linking process. This can cause mesh  102  to penetrate the HAF, which may then allow sharp edges  106  ( FIG. 1 ) and/or pressure points  202  ( FIG. 2 ) of mesh  102  to scratch the ink. Furthermore, during the cross-linking process, the HAF can flow into one or more through-holes in the glass and create visible overflow. 
     Accordingly, various approaches can be used to reduce these problems and allow HAFs to be used when applying mesh to ink-covered glass. In particular, in one embodiment, a protective layer can be laminated to the HAF. The protective layer can prevent the sharp edges and/or pressure points of the mesh from scratching the ink on the glass. In addition, the stiffness of the protective layer can prevent the HAF from shifting during application, which helps to reduce overflow. 
     Turning now to  FIG. 3 , a cross-sectional view of cosmetic surface assembly  300  on an electronic device is shown. The electronic device can include any suitable electronic device having one or more cosmetic surfaces. The term “electronic device” can include, but is not limited to, music players, video players, still image players, game players, other media players, music recorders, video recorders, cameras, other media recorders, radios, medical equipment, domestic appliances, transportation vehicle instruments, musical instruments, calculators, cellular telephones, other wireless communication devices, personal digital assistants, remote controls, pagers, computers (e.g., desktops, laptops, tablets, servers, etc.), monitors, televisions, stereo equipment, set up boxes, set-top boxes, boom boxes, modems, routers, keyboards, mice, speakers, printers, and combinations thereof. In some embodiments, the electronic device may perform a single function (e.g., a device dedicated to playing music) and, in other embodiments, the electronic device may perform multiple functions (e.g., a device that plays music, displays video, stores pictures, and receives and transmits telephone calls). 
     Cosmetic surface assembly  300  can include cosmetic surface  302 , adhesive layer  304 , and mesh  306 . Mesh  306  can be the same as or similar to mesh  102  of  FIGS. 1 and 2 . As discussed above, cosmetic surface  302  can be an area surrounding an acoustic opening on the electronic device such as ink-covered glass. For example, ink  310  can be applied to side  312  of glass  308 . In addition, cosmetic surface  302  (and glass  308 ) can include through-hole  314 , which can be surrounded by sides  316  and  318  of cosmetic surface  302 . Mesh  306  can be secured to side  312  of cosmetic surface  302  to cover through-hole  314 . Persons skilled in the art will appreciate that although cosmetic surface  302  is described as including glass  308 , cosmetic surface  302  can be formed using any suitable material. 
     Adhesive layer  304  can include cross-linked heat activated adhesives  320  and  322  on sides  324  and  326 , respectively. Cross-linked heat activated adhesives  320  and  322  can be HAFs. In particular, cross-linked heat activated adhesive  320  can secure adhesive layer  304  to side  312  of glass  308 , and cross-linked heat activated adhesive  322  can secure adhesive layer  304  to mesh  306 . Persons skilled in the art will appreciate that instead of HAFs, adhesives  320  and  322  can instead be made from another suitable adhesive material. 
     Adhesive layer  304  can include protective layer  328  between sides  324  and  326 . Protective layer  328  can be a thin layer that is made from any material suitable for protecting cosmetic surface  302  from damage. For example, protective layer  328  can be made from a non-woven paper material that has a higher melting temperature than heat activated adhesives  320  and  322 . This material can be selected to bond well with heat activated adhesives  320  and  322 . In addition, because the material can be selected to have a higher melting temperature than heat activated adhesives  320  and  322 , it will not melt or burn during the cross-linking process. This material, however, may disintegrate in wet processes (e.g., ultrasonic cleaning). 
     As another example, protective layer  328  can be made from a suitable plastic material such as polyethylene terephthalate (“PET”), polyimide (“PI”), and/or another plastic material that adheres well to heat activated adhesives  320  and  322  and is robust to moisture. 
     As yet another example, protective layer  328  can be made from a fabric of glass and/or natural fibers. As a further example, protective layer  328  can be made from a metal foil. 
     In some embodiments, protective layer  328  (e.g., metal foil) may be perforated (e.g., microperforated) in order to allow heat activated adhesives  320  and  322  to bond directly to each other. For example, the microperforation can be performed using die-cutting, laser cutting, chemical etching, any other suitable process, and/or any combination thereof. 
     In some embodiments, protective layer  328  can be a suitable porous material. This can improve both the cross-linkage of heat activated adhesives  320  and  322  to protective layer  328  and the cross-linkage of heat activated adhesives  320  and  322  to one another (e.g., “through-pore” HAF cross-linkage in which heat activated adhesive  320  is bonded to heat activated adhesive  322 ). In some cases, adhesive layer  304  can have a footprint that compensates for flow during cross-linkage. 
     Referring now to  FIG. 4 , a close-up of portion A of the cross-sectional view of assembly  300  is shown. In one embodiment, heat activated adhesive  320  can have a thickness h 1  of 0.03 mm, protective layer  328  can have a thickness h 2  of 0.02 mm, and heat activated adhesive  322  can have a thickness h 3  of 0.03 mm. Persons skilled in the art will appreciate that these thicknesses are merely illustrative, and that the various layers of assembly  300  can have any suitable thicknesses. 
       FIGS. 5A-5E  are cross-sectional views illustrating a number of steps for forming assembly  300  of  FIG. 3 .  FIG. 5A  shows laminated roll of adhesive  500  with protective layer having sides  324  and  326 . Laminated roll  500  can be generated after a first step in which protective layer  328  can be laminated between heat activated adhesive  320  on side  324  and heat activated adhesive  322  on side  326 . In some embodiments, the lamination of protective layer  328  to heat activated adhesives  320  and  322  can be performed prior to die-cutting. 
     As shown in  FIG. 5A , the adhesive thickness and material are shown as being the same on sides  324  and  326 . However, persons skilled in the art will appreciate that the adhesive thickness and/or material may be different on each side for optimum properties. For example, the adhesive thickness may be increased on the side that will be applied to mesh (e.g., side  326 ) because it can be more difficult to bond to the mesh than to a cosmetic surface (e.g., glass). 
     During lamination, heat-activated adhesives  320  and  322  can be heated below cross-linking material (e.g., cross-linked portions  402 ) to semi-attach adhesives  320  and  322  to protective layer  328 . These large laminated rolls can thus serve as a replacement product for standard HAF. The lamination can occur using one or more processes such as, for example, a heated flat-bed process, a continuous reel process between heated rollers, an application of hot air, any other suitable process(es), and/or any combination thereof. Moreover, if protective layer  328  is made from a suitable material (e.g., stainless steel foil), induction heating may also be used to laminate roll  500 . 
     The result of this lamination can be a partially cross-linked adhesive layer. In addition, heat activated adhesives  320  and  322  can each include cross-linked portions  540  and cross-linkable portions  542 . Cross-linked portions  540  can be used to secure the adhesive to the partially cross-linked adhesive layer, and cross-linkable portions  542  can be available to be cross-linked at a later time. For example, cross-linkable portions  542  can be cross-linked with a cosmetic surface and/or a mesh during subsequent processing. 
     In some cases, the cross-linkage of cross-linked portions  540  can generate water, which is an undesirable byproduct. In particular, since the area of roll  500  is relatively large, the amount of water that is generated can be substantial, which can leave bubbles within the roll. Bubbles are undesirable because they can affect the flatness of roll  500  and can introduce inconsistencies in the roll. Consequently, by running laminated roll  500  through a calendar machine, bubbles can be removed (e.g., squeezed or burned off) from the roll. 
       FIG. 5B  shows a second step in which laminated roll  500  of  FIG. 5A  can be die-cut, which forms die-cut adhesive  502 . Moreover, the die-cut can create cutout  504  in adhesive layer  502 . Sides  506  and  508  of die-cut adhesive  502  can surround cutout  504 . 
       FIG. 5C  shows a third step in which side  324  of die-cut adhesive  502  can be applied to cosmetic surface  302 . In some embodiments, cosmetic surface  302  may be heated prior to applying side  324  of die-cut adhesive  502 . 
     During this application, cutout  504  can be positioned to align with through-hole  314  of cosmetic surface  302 . In addition, as shown in  FIG. 5C , side  506  of adhesive  502  can be offset from side  316  of through-hole  314  by pre-determined distance  510 . Similarly, side  508  of adhesive  502  can be offset from side  318  of through-hole  314  by pre-determined distance  510 . This offset placement of adhesive  502  with respect to the sides of through-hole  314  can help reduce leakage during the subsequent cross-linking process. 
       FIG. 5D  shows a fourth step in which side  326  of die-cut adhesive  502  can be applied to mesh  306 . 
       FIG. 5E  shows a fifth step in which heat activated adhesive  320  can be cross-linked to secure cosmetic surface  302 , and heat activated adhesive  322  can be cross-linked to secure mesh  306 . As a result of the cross-linking process, die-cut adhesive  502  can be transformed to adhesive layer  304  ( FIGS. 3 and 4 ). 
     In some embodiments, one or more hot shoes (e.g., hot shoes  512  and  514 ) can be used for cross-linking. In particular, the hot shoe(s) can apply the heat and pressure to assembly  300  that is necessary for cross-linking. In some cases, the one or more hot shoes can be coated with a material that promotes ease of shoe removal from mesh  306  once the cross-linking process is complete. For example, the one or more hot shoes can be Teflon and/or silicone coated. 
     Hot shoe(s) can have any suitable shape such as, for example, a dish-shape, a dome-shape, a moat-shape, a u-shape, a semi-circular-shape, and/or any combination thereof. The shape of the hot shoe(s) can influence the flow of heat activated adhesives  320  and  322  during cross-linking. For example, a dish-shaped shoe can force the flow away from cosmetic surface  302 . 
     During cross-linking, it is desirable to minimize overflow in certain locations (e.g., sides  316  and  318  of through-hole  314 ). Consequently, different types of hot shoe(s) can be used to direct the flow of heat activated adhesives  320  and  322 . In one embodiment, for example, shoe  512  can be applied first. Shoe  512  can be a u-shaped shoe that provides a precise application of heat and pressure. Thus, the application of shoe  512  to cross-link first portion  516  of heat activated adhesive  320  can create dams  518  at sides  316  and  318  of through-hole  314 . In other embodiments, instead of using shoe  512  to create dams  518 , ink dams can be pre-formed on cosmetic surface  302 . 
     After applying shoe  512 , shoe  514  can be used to apply heat and pressure to cross-link the remaining portions of heat activated adhesives  320  and  322 . In some cases, shoe  514  can be dome-shaped. The dome-shaped shoe can help to prevent leakage of heat activated adhesives  320  and  322  beyond sides  506  and  508  of adhesive layer  304 . Additionally, dams  518  (e.g., pre-formed on cosmetic surface  302  or created by shoe  512 ), can prevent heat activated adhesives  320  and  322  from leaking into through-hole  314 . 
       FIGS. 6A-6E  are cross-sectional views illustrating a number of steps for forming another assembly for protecting a cosmetic surface.  FIG. 6A  shows glass  308  having side  312 . 
       FIG. 6B  shows a second step in which ink  310  can be applied to side  312  of glass  308 . Persons skilled in the art will appreciate that ink  310  can be applied to glass  308  using any suitable technique. In one example, ink  310  can be screen-printed over side  312  of glass  308 . 
       FIG. 6C  shows a third step in which a layer of hard-coat  602  can be applied to side  312  of glass  308  over ink  310 . In some embodiments, hard-coat  602  can be screen printed over ink  310 . Persons skilled in the art will appreciate that hard-coat  602  can be applied in any suitable manner (e.g., in a manner that is similar to the way in which ink  310  is applied to glass  308 ). 
       FIG. 6D  shows a fourth step in which side  604  of heat activated adhesive  608  is applied to side  312  of glass  308  and side  606  of heat activated adhesive  608  is applied to mesh  306 . As a result, mesh  306  can cover through-hole  314  of glass  308 . 
       FIG. 6E  shows a fifth step in which assembly  610  is created by cross-linking heat activated adhesive  608  to secure glass  308  and mesh  306 . In some embodiments, hot shoe  612  can be used for the cross-linking. Because of the placement of hard-coat  602  between heat activated adhesive  608  and the ink-covered glass, hard-coat  602  can prevent heat activated adhesive  608  from scratching ink  310 . 
     Although not shown, persons skilled in the art will appreciate that a hybrid assembly can be used for protecting cosmetic surfaces, where the hybrid assembly can include both a hard coat layer and a center layer between heat activated adhesives. 
     Turning now to  FIGS. 7A-9 , various methods for cross-linking of heat activated adhesives and preventing adhesive overflow are shown. For the sake of simplicity, mesh  306  is shown as a light gray layer in  FIGS. 7A-9 . 
       FIGS. 7A-7C  are perspective views of the successive application of different hot shoes to a cosmetic surface assembly in accordance with some embodiments of the invention. Hot shoes  702 - 706  can be used to progressively cross-link heat activated adhesives  320  and  322 . That is, hot shoe  702  can be applied to adhesive layer  304  first, followed by hot shoe  704  and then hot shoe  706 . Each hot shoe  702 - 706  can have increasingly wider-spaced arms, which can allow different portions of heat activated adhesives  320  and  322  to be cross-linked. The direction of force applied by each hot shoe is indicated by the corresponding arrows in  FIGS. 7A-7C . 
     Significantly, each of hot shoes  702 - 706  can only be applied to portions of cosmetic surface assembly  300  that are outward from the perimeter of through-hole  314  (e.g., areas that border sides  316  and  318  of through-hole  314 ). This can help to ensure that heat activated adhesives  320  and  322  do not overflow into through-hole  314 . 
       FIG. 8  is a cross-sectional view of one approach for applying pressure to a cosmetic surface assembly. Side  802  of cosmetic surface  302  can be applied to fixture  804 . Hot shoe  806  having through-hole  808  can be applied to side  326  of adhesive layer  304 . Moreover, hot shoe  806  can be applied in such a manner that through-hole  808  of hot shoe  806  can line up with through-hole  314  of cosmetic surface  302 . Seal  810 , which can be a silicone seal, can be coated on side  812  of hot shoe  806 . 
     To cross-link heat activated adhesives  320  and  322 , hot shoe  806  can apply a force to assembly  300  in the direction indicated by the arrows in  FIG. 8 . In addition, while hot shoe  806  is being applied to assembly  300 , a positive pressure can be applied to the center of mesh  306 . In particular, seal  810  can be used to seal hot shoe  806  to the rest of fixture  804  (not shown in  FIG. 8 ) such that chamber  814  can become pressurized. Because chamber  814  is pressurized higher than the surrounding air, overflow from heat activated adhesives  320  and  322  can be directed away from chamber  814 . 
       FIG. 9  is a cross-sectional view of another approach for applying pressure to a cosmetic surface assembly in accordance with some embodiments of the invention. In particular, side  802  of cosmetic surface  302  can be applied to fixture  902 . Fixture  902  can have an opening  904 . Thus, in some embodiments, opening  904  of fixture  902  can be positioned to line up with through-hole  314  of cosmetic surface  302 . 
     Hot shoe  906  having through-hole  908  can be applied to side  326  of adhesive layer  304 . Moreover, hot shoe  906  can be applied in such a manner that through-hole  908  can line up with through-hole  314  of cosmetic surface  302 . 
     To cross-link heat activated adhesives  320  and  322 , hot shoe  908  can apply a force to assembly  300  in the direction indicated by the arrows in  FIG. 9 . In addition, while hot shoe  906  is being applied to assembly  300 , the portion of mesh  306  covering the center of through-hole  314  can be cooled. For example, a high velocity air jet applied in a direction indicated by the dashed line can be used to cool the air surrounding this portion of mesh  306 . This can help to reduce adhesive overflow during the cross-linking process. 
       FIG. 10  is a flowchart of an illustrative manufacturing process  1000  for creating an assembly for protecting cosmetic surfaces. Process  1000  may start at step  1002 , and, at step  1004 , a roll of adhesive having first and second sides (e.g., sides  324  and  326  of  FIG. 5A ) can be laminated. In particular, a protective layer (e.g., protective layer  328  of  FIG. 5A ) can be laminated between a first layer of heat activated adhesive (e.g., heat activated adhesive  320  of  FIG. 5A ) on the first side of the roll and a second layer of heat activated adhesive (e.g., heat activated adhesive  322  of  FIG. 5A ) on the second side of the roll. 
     At step  1006 , the laminated roll (e.g., laminated roll  500  of  FIG. 5A ) of the adhesive can be die-cut. For example, as shown in  FIG. 5B , laminated roll  500  of  FIG. 5A  can be die-cut to form die-cut adhesive  502 . 
     At step  1008 , the first side of the die-cut adhesive can be applied to a cosmetic surface (e.g., cosmetic surface  302  of  FIG. 5C ) of an electronic device. Then, at step  1010 , the second side of the die-cut adhesive can be applied to a mesh (e.g., mesh  306  of  FIG. 5D ). 
     Continuing to step  1012 , the first layer of the heat activated adhesive can be cross-linked to secure the cosmetic surface, and the second layer of the heat activated adhesive can be cross-linked to secure the mesh. In some embodiments, as shown in  FIGS. 5E  and  7 A- 7 C, one or more hot shoes (e.g., hot shoes  512  and  514 ) can be used in the cross-linking process. Process  1000  may then end at step  1014 . 
       FIG. 11  is a flowchart of another illustrative manufacturing process  1100  for creating an assembly for protecting cosmetic surfaces. Process  1100  may start at step  1102 , and, at step  1104 , ink (e.g., ink  310  of  FIG. 6B ) can be applied to a first side (e.g., side  312  of  FIG. 6B ) of a glass surface (e.g., glass  308  of  FIG. 6B ) of an electronic device. 
     At step  1106 , a layer of hard-coat (e.g., hard-coat  602  of  FIG. 6C ) can be applied to the first side of the glass surface over the ink. Then, at step  1108 , a first side (e.g., side  604  of  FIG. 6D ) of a heat activated adhesive (e.g., heat activated adhesive  608  of  FIG. 6D ) can be applied to the first side of the glass surface, and a second side (e.g., side  606  of  FIG. 6D ) of the heat activated adhesive can be applied to a mesh (e.g., mesh  306  of  FIG. 6D ) such that the mesh covers a through-hole (e.g., through-hole  314  of  FIG. 6D ) of the glass surface. 
     At step  1110 , the heat activated adhesive can be cross-linked to secure the glass surface and the mesh to the heat activated adhesive. For example, as shown in  FIG. 6E , one or more hot shoes (e.g., hot shoe  612 ) can be used in the cross-linking process. Process  1100  may then end at step  1112 . 
     While there have been described assemblies for the protection of cosmetic surfaces, it is to be understood that many changes may be made therein without departing from the spirit and scope of the invention. It is also to be understood that processes  700  and  800  of  FIGS. 7 and 8  are merely illustrative. Any of the steps may be removed, modified, or combined, and any additional steps may be added, without departing from the scope of the invention. 
     The described embodiments of the invention are presented for the purpose of illustration and not of limitation.

Metadata:
Filing Date: 20120907
Publication Date: 20150407
Grant Date: 20150407
Priority Date: 20120907
Inventors: BERG ANDREW M.
WITTENBERG MICHAEL B.
COHEN SAWYER I.
Assignee: APPLE INC
CPC Classifications: [{"code": "B32B7/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T156/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K5/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L21/64", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T428/24959", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24322", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/1039", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2461/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/0242", "inventive": true, "first": false, "tree": "[]"}, {"code": "C09J2203/326", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/108", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/0203", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T156/1062", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/2826", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "C09J2201/128", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B7/027", "inventive": true, "first": true, "tree": "[]"}, {"code": "B32B7/027", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T156/1062", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T156/108", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B17/067", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/24331", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/35", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/24331", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/2826", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2203/326", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24959", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/1039", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24322", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J7/35", "inventive": true, "first": false, "tree": "[]"}, {"code": "C09J2301/124", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/2826", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B17/067", "inventive": true, "first": false, "tree": "[]"}, {"code": "C09J2301/124", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/1062", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24959", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24322", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2461/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/108", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2203/326", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T156/1039", "inventive": false, "first": false, "tree": "[]"}, {"code": "C09J2461/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01L21/64", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 50233558