PATENT DOCUMENT

Publication Number: US-7756553-B2
Application Number: US-65092307-A
Country: US
Kind Code: B2

Title: Folded flex assembly for personal media device

Abstract:
Systems and methods are provided for media devices including a housing, a frame disposed adjacent to the housing, a support panel that is integrated with the frame, and a flexible circuit that is disposed adjacent to the support panel such that the support panel provides support for the flexible circuit.

Claims:
1. A media device comprising:
 a housing, 
 a frame disposed adjacent to the housing, 
 a support component comprising:
 a support arm coupled to the frame; and 
 a support panel coupled to the support arm, wherein the support panel and the support arm are coupled such that the support panel is displaced from the frame, and 
 
 a flexible circuit disposed adjacent to the support panel to provide support for the flexible circuit, wherein the flexible circuit includes:
 a first portion; 
 a second portion; and 
 a fold located between the first portion and the second portion such that the first portion and the second portion of the flexible circuit fold around at least a portion of the support panel. 
 
 
     
     
       2. The device of  claim 1 , wherein integrated with includes detachably connected to. 
     
     
       3. The device of  claim 1 , wherein integrated with includes unitarily formed with. 
     
     
       4. The device of  claim 1 , wherein integrated with includes mounted to. 
     
     
       5. The device of  claim 1 , wherein the frame is disposed substantially within the housing. 
     
     
       6. The device of  claim 1 , wherein the frame includes a backplane. 
     
     
       7. The device of  claim 1 , wherein the first portion is adjacent to a first surface of the support panel. 
     
     
       8. The device of  claim 7 , wherein the second portion is adjacent to a second surface of the support panel. 
     
     
       9. The device of  claim 1 , wherein the flexible circuit further includes at least one of an acoustic source, a microphone, a proximity sensor, a light sensor, and a light source. 
     
     
       10. The device of  claim 1 , wherein the first portion is positioned between at least a portion of a bottom surface of the support panel and at least a portion of the frame and the second portion is positioned above at least a portion of a top surface of the support panel. 
     
     
       11. The device of  claim 1 , wherein the support panel is substantially parallel to the frame. 
     
     
       12. A method for emitting a sound from a media device comprising:
 integrating a support panel with a frame of the media device, wherein the support panel comprises a bottom surface and a top surface, 
 positioning a portion of a flexible circuit adjacent to the support panel, wherein the flexible circuit includes a fold such that a first portion of the flexible circuit is positioned between at least a portion of the bottom surface of the support panel and at least a portion of the frame and a second portion of the flexible circuit is positioned above at least a portion of the top surface of the support panel, 
 integrating an acoustic source with the flexible circuit, and 
 emitting sound from the acoustic source to an external aperture of the media device. 
 
     
     
       13. The method of  claim 12 , wherein integrating includes detachably connecting to. 
     
     
       14. The method of  claim 12 , wherein integrating includes unitarily forming with. 
     
     
       15. The method of  claim 12 , wherein integrating includes mounting to. 
     
     
       16. The method of  claim 12 , wherein the frame is disposed substantially within the housing. 
     
     
       17. The method of  claim 12 , wherein the first portion is adjacent to the bottom surface of the support panel. 
     
     
       18. The method of  claim 12 , wherein the second portion is adjacent to the top surface of the support panel. 
     
     
       19. The method of  claim 12 , wherein the fold is between the first and second portion for folding the first and second portion of the flexible circuit around at least a portion of the support panel. 
     
     
       20. The method of  claim 12 , wherein the flexible circuit further includes at least one of a microphone, a proximity sensor, a light sensor, and a light source. 
     
     
       21. The method of  claim 12 , wherein the support panel further comprises a support arm coupling the support panel to the frame such that the bottom and top surface of the support panel are displaced from the frame. 
     
     
       22. The method of  claim 12 , where positioning a portion comprises:
 positioning a first portion of the support panel between the frame and a bottom surface of the support panel; and 
 positioning a second portion of the support panel above a top surface of the support panel, and wherein the fold couples the first portion to the second portion. 
 
     
     
       23. A method for manufacturing a media device comprising:
 providing a housing, 
 attaching a frame to the housing, 
 coupling a support arm to the frame, 
 coupling a support panel to the support arm, wherein the support arm displaces the support panel from the frame, and 
 positioning a portion of a flexible circuit adjacent to the support panel, wherein the flexible circuit includes a fold such that the flexible circuit is folded around at least a portion of the support panel. 
 
     
     
       24. The method of  claim 23 , wherein positioning a portion includes positioning a first portion of the flexible circuit adjacent to a first surface of the support panel. 
     
     
       25. The method of  claim 24 , wherein positioning a portion further includes positioning a second portion of the flexible circuit adjacent to a second surface of the support panel. 
     
     
       26. The method of  claim 25 , wherein positioning a portion further includes folding the first and second portions such that the first and second portions of the flexible circuit surround at least a portion of the support panel.

Description:
BACKGROUND 
     This invention relates to personal media devices and, more particularly, to a folded flex assembly for personal media devices. 
     The proliferation of compact portable personal media devices (e.g., portable MP3 players, portable video players, and media capable cellular telephones) has created a need for even more compact and feature rich media devices. 
     One problem with existing media devices such as cellular telephones is that the media device has limited space available on it&#39;s internal circuit board or boards to support various media, communications, and other processing features that typical users now desire in a compact media device. Accordingly, there is a need for more efficiently arranging the various components within a media device to, for example, enable the inclusion of more components that support more service features. 
     Another problem with existing media devices is that the configuration or arrangement of various internal components is constrained by the size or position of the circuit board or boards, and their components, within the media device. The need to arrange a component or components at certain circuit board locations can effect the overall size, shape, or form-factor of a media device. Accordingly, there is a need for more flexible arrangement of internal components in a media device to enable more flexible design of the size, shape, or form-factor of a media device. 
     Another problem with existing media devices is that certain internal components are susceptible to physical stresses such as physical shock or vibrations that can degrade the performance of these components. Accordingly, there is a need to provide more structural rigidity for certain internal components to enhance performance and make the media device more robust and reliable in an environment subject to physical stresses. 
     SUMMARY 
     The invention, in various embodiments, addresses deficiencies in the prior art by providing systems, methods and devices that enhance the ability of a compact media device to support flexible arrangements of more components and, thereby, support more features while also providing enhanced structural support for certain components. 
     In various aspects, the invention employs an flexible circuit and/or flex assembly that is integrated with the frame. The flex assembly may include one or more components that would otherwise be mounted on the media device&#39;s circuit board. The component or components may include an acoustic source, proximity sensor, and/or light sensor. By including the components on the flexible circuit rather than the circuit board, space is made available on the circuit board for other components that may support other features. For example, by mounting an acoustic source on the flexible circuit, a SIMM tray or receptacle may be included on the media device&#39;s circuit board to enable SIMM card based services. The term “integrated with” may include integrally formed with, unitarily formed with, attached to, detachably connected to, mounted on, or any like permanent, semi-permanent, or temporary configuration whereby an element, or a portion thereof, is in physical communication or contact with another element of the media device. An acoustic source may include a speaker assembly or acoustic receiver which is not the same as a radio frequency (RF) receiver. 
     In one aspect, a media device includes a housing, a frame disposed adjacent to the housing, a support panel being integrated with the frame, and a flexible circuit disposed adjacent to the support panel to provide support for the flexible circuit. The frame may be disposed substantially within the housing. The frame may include a backplane. The flexible circuit may include a first portion adjacent to a first surface of the support panel. The flexible circuit may include a second portion adjacent to a second surface of the support panel. The flexible circuit may include a fold between the first and second portion for folding the first and second portion of the flexible circuit around a portion of the support panel. The flexible circuit may further include at least one of an acoustic source, a microphone, a proximity sensor, a light sensor, and a light source. 
     Another aspect includes a method for emitting a sound from a media device including: integrating a support panel with a frame of the media device, positioning a portion of a flexible circuit adjacent to the support panel, integrating an acoustic source with the flexible circuit, and emitting sound from the acoustic source to an external aperture of the media device. 
     A further aspect includes a method for manufacturing a media device including: providing a housing, attaching a frame to the housing, integrating a support panel with the frame, and positioning a portion of a flexible circuit adjacent to the support panel. 
     Various advantages and applications using a flex assembly integrated with a media device frame in accordance with principles of the present invention are discussed in more detail below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the present invention, its nature and various advantages 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. 1A  is a perspective view of a media device with an exposed frame assembly according to an illustrative embodiment of the invention; 
         FIG. 1B  is another perspective view of a media device according to an illustrative embodiment of the invention; 
         FIG. 2  shows the media device of  FIGS. 1A and 1B  with tethered headphones and, alternatively, a wireless earpiece according to an illustrative embodiment of the invention; 
         FIG. 3  shows a simplified functional block diagram of a media device according to an illustrative embodiment of the invention; 
         FIG. 4  shows a transverse sectional view of a conventional cellular telephone; 
         FIG. 5  shows an exploded perspective view of the various sections of a conventional cellular telephone including a frame; 
         FIG. 6  shows a transverse sectional view of a media device including a flexible circuit according to an illustrative embodiment of the invention; 
         FIG. 7  shows a perspective view of a frame including a support panel according to an illustrative embodiment of the invention; 
         FIGS. 8A-8C  show a perspective views of support panels for a flexible circuit according to an illustrative embodiment of the invention. 
         FIG. 9  shows a transverse view of a flex assembly including a flexible circuit according to an illustrative embodiment of the invention; 
         FIG. 10  shows a transverse view of a flex assembly including a flexible circuit having support panels according to an illustrative embodiment of the invention; 
         FIG. 11  shows a top down view of a flex assembly including a flexible circuit according to an illustrative embodiment of the invention; 
         FIG. 12  shows a top down view of a flex assembly including a flexible circuit having support panels according to an illustrative embodiment of the invention; 
         FIG. 13  shows a perspective view of a flex assembly including the components shown in  FIGS. 11 and 12  along with an acoustic source according to an illustrative embodiment of the invention; 
         FIG. 14  shows a perspective view of a flex assembly integrated with a frame according to an illustrative embodiment of the invention; 
         FIG. 15  shows another perspective view of a flex assembly integrated with a frame according to an illustrative embodiment of the invention; 
         FIG. 16  shows a transverse sectional view of a flex assembly integrated with a frame according to an illustrative embodiment of the invention; 
         FIG. 17  shows another transverse sectional view of a flex assembly integrated with a frame according to an illustrative embodiment of the invention; and 
         FIG. 18  is a flow chart of a process for manufacturing a media device according to an illustrative embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
       FIG. 1A  is a perspective view of a media device  100  according to an illustrative embodiment of the invention. The media device  100  includes a housing  102 , a first housing portion  104 , a second housing portion  106 , a display  108 , a keypad  110 , a speaker housing aperture  112 , a microphone housing aperture  114 , a headphone jack  116 , and frame sidewall  122 . Although not shown, in certain embodiments, the frame sidewall  122  is the exposed portion of a frame residing within or adjacent to the housing  102  that provides structural support for the media device  100  and various internal components. The housing  102  also includes various gaps  118  that may include openings, separations, vents, or other pathways between elements of the housing  102  that enable the passage of air or sound through the housing  102 . 
     In one embodiment, the housing  102  includes a first housing portion  104  and a second housing portion  106  that are fastened together to encase various components of the media device  100 . In certain embodiments, the housing  102  also includes an exposed frame  120  that provides structural support for the media device  100 . The housing  102  and its housing portions  104  and  106  may include polymer-based materials that are formed by, for example, injection molding to define the form factor of the media device  100 . In one embodiment, the housing  102  surrounds and/or supports internal components such as, for example, one or more circuit boards having integrated circuit components, internal radio frequency (RF) circuitry, an internal antenna, a speaker, a microphone, a hard drive, a processor, and other components. Further details regarding certain internal components are discussed later with respect to  FIG. 3 . The housing  102  provides for mounting of a display  108 , keypad  110 , external jack  116 , data connectors, or other external interface elements. The housing  102  may include one or more housing apertures  112  to facilitate delivery of sound, including voice and music, to a user from a speaker within the housing  102 . The housing  102  may including one or more housing apertures  114  to facilitate the reception of sounds, such as voice, for an internal microphone from a media device user. 
     In certain embodiments, the housing  102  includes one or more gaps  118  associated with the housing  102 . These gaps  118  may result from the manufacturing and/or assembly process for the media device  100 . For example, in certain circumstances, the mechanical attachment of the first housing portion  104  with the second housing portion  106  or the sidewall  122  results in a crease  120  or joint between the portions  104  and  106 . In certain media devices  100 , the crease  120  is not air tight, resulting in gaps  118  along the crease. Other gaps may be formed during assembly between, for example, one or more keys of the keypad  110  and the housing  102  or the display  108  and the housing  102 , resulting in additional gaps  118 . In other embodiments, the housing  102  may include addition portions that are integrated to form the housing  102  for the media device  100 . 
     The media device  100  may include a wireless communications device such as a cellular telephone, satellite telephone, cordless telephone, personal digital assistant (PDA), pager, portable computer, or any other device capable of wireless communications. In fact,  FIG. 1  shows an exemplary cellular telephone version of a broad category of media device  100 . 
     The media device  100  may also be integrated within the packaging of other devices or structures such a vehicle, video game system, appliance, clothing, helmet, glasses, wearable apparel, stereo system, entertainment system, or other portable devices. In certain embodiments, device  100  may be docked or connected to a wireless enabling accessory system (e.g., a wi-fi docking system) that provides the media device  100  with short-range communicating functionality. Alternative types of media devices  100  may include, for example, a media player such as an ipod available by Apple Computer Inc., of Cupertino, Calif., pocket-sized personal computers such as an iPAQ Pocket PC available by Hewlett Packard Inc., of Palo Alto, Calif. and any other device capable of communicating wirelessly (with or without the aid of a wireless enabling accessory system). 
     In certain embodiments, the media device  100  may synchronize with, for example, a remote computing system or server to receive media (using either wireless or wireline communications paths). Wireless syncing enables the media device  100  to transmit and receive media and data without requiring a wired connection. Media may include, without limitation, sound or audio files, music, video, multi-media, and digital data, in streaming and/or discrete (e.g., files and packets) formats. 
     During synchronization, a host system may provide media to a client system or software application embedded within the media device  100 . In certain embodiments, media and/or data is “downloaded” to the media device  100 . In other embodiments, the media device  100  is capable of uploading media to a remote host or other client system. Further details regarding the capabilities of certain embodiments of the media device  100  are provided in U.S. patent application Ser. No. 10/423,490, filed on Apr. 25, 2003, the entire contents of which are incorporated herein by reference. 
       FIG. 1B  is another perspective view of a media device  100  according to an illustrative embodiment of the invention. In this embodiment, as opposed to the embodiment of  FIG. 1A , the media device&#39;s frame and/or the frame&#39;s sidewalls are not exposed to an external surface of the device. However, in certain embodiments, the frame is connected internally with at least a portion of one of the first housing portion  104  or the second housing portion  106 . 
       FIG. 2  shows the media device  100  of  FIG. 1  with tethered headphones  200  and, alternatively, a wireless earpiece  206  according to an illustrative embodiment of the invention. The tethered headphones  200  include a cable  212  that connects to the media device  100  via external jack  116 . In one embodiment, the cable provides for transport of an audio signal from the media device  100  to the headphones  100 . In another embodiment, the headphones  200  includes a left housing  202  and a right housing  204 , corresponding to the left and right ears of a user, respectively. Each housing  202  and  204  may include a speaker and/or an acoustic assembly as described later with respect to  FIG. 4 . The headphones  200  may optionally include a microphone to facilitate sending sounds from the user to the media device  100 . As an alternative to the headphones  200 , a user may utilize the wireless earpiece  206  which includes a housing  208 . In one embodiment, the earpiece  206  employs wireless channel  210  to receive audio signals from the device  100  or transmit audio signals to the device  100 . The housing  208  may include a speaker, microphone, and/or acoustic assembly as described later with respect to  FIG. 4 . 
       FIG. 3  shows a simplified functional block diagram of the media device  100  according to an illustrative embodiment of the invention. The media device or player  300  may include a processor  302 , storage device  304 , user interface  308 , display  310 , CODEC  312 , bus  318 , memory  320 , communications circuitry  322 , a speaker or transducer  324 , and a microphone  326 . Processor  302  may control the operation of many functions and other circuitry included in media player  300 . Processor  302  may drive display  310  and may receive user inputs from user interface  308 . 
     Storage device  304  may store media (e.g., music and video files), software (e.g., for implanting functions on device  300 , preference information (e.g., media playback preferences), lifestyle information (e.g., food preferences), exercise information (e.g., information obtained by exercise monitoring equipment), transaction information (e.g., information such as credit card information), wireless connection information (e.g., information that may enable media device to establish wireless communication with another device), subscription information (e.g., information that keeps tracks of podcasts or television shows or other media a user subscribes to), and any other suitable data. Storage device  304  may include one more storage mediums, including for example, a hard-drive, permanent memory such as ROM, semi-permanent memory such as RAM, or cache. 
     Memory  320  may include one or more different types of memory which may be used for performing device functions. For example, memory  320  may include cache, ROM, and/or RAM. Bus  318  may provide a data transfer path for transferring data to, from, or between at least storage device  304 , memory  320 , and processor  302 . Coder/decoder (CODEC)  112  may be included to convert digital audio signals into an analog signal for driving the speaker  324  to produce sound including voice, music, and other like audio. The CODEC  112  may also convert audio inputs from the microphone  326  into digital audio signals. 
     User interface  308  may allow a user to interact with the media device  300 . For example, the user input device  308  can take a variety of forms, such as a button, keypad, dial, a click wheel, or a touch screen. Communications circuitry  322  may include circuitry for wireless communication (e.g., short-range and/or long range communication). For example, the wireless communication circuitry may be wi-fi enabling circuitry that permits wireless communication according to one of the 802.11 standards. Other wireless network protocols standards could also be used, either in alternative to the identified protocols or in addition to the identified protocol. Other network standards may include Bluetooth, the Global System for Mobile Communications (GSM), and code divisional multiple access (CDMA) based wireless protocols. Communications circuitry  322  may also include circuitry that enables device  300  to be electrically coupled to another device (e.g., a computer or an accessory device) and communicate with that other device. 
     In one embodiment, the media device  300  may be a portable computing device dedicated to processing media such as audio and video. For example, media device  300  may be a media player (e.g., MP3 player), a game player, a remote controller, a portable communication device, a remote ordering interface, an audio tour player, or other suitable personal device. The media device  300  may be battery-operated and highly portable so as to allow a user to listen to music, play games or video, record video or take pictures, communicate with others, and/or control other devices. In addition, the media device  300  may be sized such that it fits relatively easily into a pocket or hand of the user. By being handheld, the media device  300  (or media device  100  shown in  FIG. 1 ) is relatively small and easily handled and utilized by its user and thus may be taken practically anywhere the user travels. 
     As discussed previously, the relatively small form factor of certain prior art media devices has constrained the ability of these media devices to protect certain acoustic components such as speaker or microphone assemblies from damaging physical forces. Also, the quality of sound emitted from an acoustic source or received by an acoustic receptor has been adversely effected by the supporting structure or structures for these acoustic components. For example, a speaker that is mounted on a circuit board may be susceptible to vibrations that are propagated along the circuit board structure which can introduce interference or noise into the speaker&#39;s sound output. Accordingly, embodiments of the invention provide for improved sound quality and enhanced structural support for acoustic components such as an acoustic source. 
       FIG. 4  shows a transverse sectional view of a conventional cellular telephone  400 . The conventional cellular telephone  400  comprises an upper housing  402 . The main structural frame  404  is secured to the housing  402  which may be fabricated from a die-castable material using a die-casting process. The frame  404  includes a surrounding sidewall  406  and a web or backplane  408 . The web  408  extends between the sidewall  406  and forms a printed circuit board compartment between the housing  402  and web  408 . The printed circuit board compartment is bounded on the top by the housing  402  and on the bottom by the web  408 . The printed circuit board compartment includes a printed circuit board  410  and associated electrical components  412 . The web  408  supports or houses a battery  414  which, in turn, forms the back of the cellular telephone  400 . The conventional cellular telephone  400  employs a unitized frame member  404  which is composed of a single die-castable material, typically magnesium or zinc, where the sidewall  406  and the web  408  are constructed of the same or different material via a die-cast fabrication technique. 
       FIG. 5  shows an exploded perspective view of the various sections of a conventional cellular telephone  500  including a frame  502 . The cellular telephone  500  generally comprises an upper enclosure or housing  504 , a printed circuit board  506 , the structural frame member  502 , and a battery  508 . As shown in  FIG. 5 , there are a number of features formed on the housing  504  that correspond with components located on the printed circuit board  506 . For example, disposed on the exterior face of the housing  504  is a display panel aperture  510  that corresponds with a display panel  512  disposed on the printed circuit board  506 . 
     Adjacent to the display panel aperture  510  is an earphone or speaker aperture  514  that corresponds with a speaker component or assembly  516  on the printed circuit board  506 . Also disposed on the face of the housing  504  is an array of keypad apertures  518  that corresponds with a tactile keypad component  520  mounted on the printed circuit board  506 . A microphone aperture  522  is located adjacent the keypad apertures  518  that corresponds with a microphone component or assembly  524  which is mounted on the printed circuit board  506 . 
     The cellular telephone  500  includes a structural frame  502 , that also includes a surrounding sidewall  526  and a web or backplane  528 . An antenna receptacle  530  is formed as part of the frame  502  that enables the transfer of radio frequency (RF) communications with the enclosed printed circuit board  506 . The sidewall  526  is formed through a die-casting process using material such as magnesium or zinc or alloys of each. The term die-cast typically refers to a structure formed by a process wherein the casting material is melted into a liquid phase and poured into a die-cast mold. The casting material then assumes the shape of the mold upon cooling and solidification. 
     The backplane  528  typically includes a thin, high strength formed structure, such as a plate of stainless steel. A formed structure typically includes components that have been stamped, pressed, punched, rolled or otherwise fabricated while the formed material is in a solid phase. The thin plate or backplane  528  is typically secured to the sidewall  526  using a mechanical or die-casting technique. 
     The backplane  528  typically extends between the surrounding sidewall  526  and divides the enclosed interior space into a printed circuit board compartment and a battery compartment. The printed circuit board compartment is typically bounded on the top by the housing  504 , and on the bottom by the backplane  528 . The printed circuit board compartment typically contains the printed circuit board  506  and various associated electrical components. The backplane  528  also acts as an upper boundary for the battery compartment. The battery pack  508  can be attached to the frame  502  and forms the back of the cellular telephone  500 . It should be understood that the frame  528  typically establishes front and back compartments on each side of the backplane  528 . 
       FIG. 6  shows a transverse sectional view of a media device  600  including a flexible circuit  622  according to an illustrative embodiment of the invention. The media device  600  comprises an upper housing  602 , lower housing  604 , a frame  606 , a printed circuit board  608 , printed circuit board components  610 , and an acoustic source  612 , a printed circuit board cavity  618 , a second cavity  620 , a flexible circuit  622 , a flexible circuit connector  624 , a proximity sensor emitter  626 , a proximity sensor receiver  628 , an light emitting diode (LED)  630 , an ambient light sensor  638 , a driver circuit  632 , a support panel  634 , and a support panel arm  636 . In one embodiment, the proximity sensor emitter and receiver  626  and  628  are infra-red (IR) based emitter and receivers. The driver circuit  632  may provide driving and/or interfacing circuitry for at least one of the acoustic source  612 , proximity sensor emitter  626 , proximity sensor receiver  628 , ambient light sensor  638 , light emitting diode (LED)  630 , and any other component, such as a microphone, mounted to the flexible circuit  622 . 
     The frame  606  may include a sidewall or sidewalls  614  and a backplane  616 . In one embodiment, the main structural frame  606  is secured to at least one of the upper housing  602  and lower housing  604 . At least a portion of the housings  602  and  604  may be fabricated from a die-castable material using a process including die-casting, molding, injection-type molding, and/or the like. In certain embodiments, the support panel  634  includes at least one arm  636 , both of which are made of a metal such as, without limitation, steel or a steel alloy. In another embodiment, the at least one arm  636  may be configured to snap into a complementary feature of the frame  606  to provide attachment to the frame  606 . 
     In one embodiment, the frame  606  includes a surrounding sidewall  614  or plurality of sidewalls  614  and a web or backplane  616 . The web  616  extends between the sidewall  614  or between two or more sidewalls  614  to form a printed circuit board compartment  618  between the upper housing  602  and the web  616 . Thus, the printed circuit board compartment  618  may be bounded on the top by the upper housing  602  and on the bottom by the web  616 . In certain embodiments, the sidewall  614  extends completely along the perimeter of the frame  606 . Alternatively, the sidewall  614  extends along one or more portions of the perimeter of frame  606 , effectively forming a plurality of sidewalls  614 . In one embodiment, the frame  606  does not have a sidewall  614 , but is connected to or integrated with at least one of the upper housing  602  and the lower housing  604  or integrated with at least one of the first housing portion  104  and the second housing portion  106  of the media device  100 . 
     In certain embodiments, the web  616  and lower housing  604  form a second compartment  620  that contains a battery and/or electrical components. The media device  600  may employ a unitized or composite frame  606  that includes a die-castable material, such as magnesium or zinc, where the sidewalls  614  and the web  616  are constructed of the same or different materials via a die-cast and/or assembly fabrication technique. The frame may also include steel, stainless steel, an alloy of steel, or any like metal. The assembly fabrication technique may include connecting one or more portions of the frame  606  together using glue, one or more mechanical connectors, or another like attachment mechanism or medium. 
     In certain embodiments, the flexible circuit  622  includes circuit traces that run from the connector  624  to one or more components, such as acoustic source  612  and provide an electrical connection between the components mounted to the flexible circuit  622  and components of the circuit board  608 . The circuit board  608  may include one or more of the components shown in  FIG. 3  such as the processor  302  or CODEC  312 . 
     In one embodiment, the flexible circuit  622  folds around the support  634  to form a flex assembly including the flexible circuit  622 , support panel  634 , and at least one of the proximity sensor emitter  626 , proximity sensor receiver  628 , light emitting diode (LED)  630 , driver circuit  632 , or any other circuit mounted to the flexible circuit  622 . In one embodiment, the flexible circuit  622  includes a polymer-based and/or plastic material. In another embodiment, the flexible circuit can flexibly move or pivot about at least one location of its structure. In a further embodiment, the flexible circuit  622  is folded such that a first portion is adjacent to and/or in contact with a first or top surface of the support panel  634 . In yet a further embodiment, the flexible circuit  622  is folded such that a second portion is adjacent to and/or in contact with a second or bottom surface of the support panel  634 . At least one component mounted to the flexible circuit  622  may also be in physical communication or integrated with the support panel  634  and/or the frame  606 . The flexible circuit  622  may also be integrated with the support panel  634  and/or frame  606 . 
     In certain embodiments, the acoustic source  612 , e.g., a speaker assembly, is also integrated with the frame  606  and/or with the support panel  634  as shown in  FIG. 6 . The acoustic source  612  may include an acoustic assembly which may have, for example, a speaker subassembly including a diaphragm and other speaker components. By integrating the acoustic source  612  with the support panel  634  and/or the frame  606 , either or both the support panel  634  and the frame  606  advantageously protect the acoustic source  612  and its components from external forces and/or mitigate the effects of vibration or other interference. The support panel  634  and/or frame  606  may provide like support for any components integrated with the flexible circuit  622 . Thus, in certain embodiments, the support panel  634  provides enhanced structural rigidity and support to flexible circuit  622  and/or one or more of the components that are integrated with the flexible circuit  622 . 
     The frame  606  may include one or more apertures, cutouts, openings, and/or recesses to provide support for the flexible circuit  622  and/or any other component integrated with the flexible circuit  622 . In one embodiment, the sidewall  614  includes at least one aperture to enable the transport of sound from the acoustic source  612  to outside of the media device  600 . 
       FIG. 7  shows a perspective view of a frame  700  including support panels  702 ,  704 , and  706  according to an illustrative embodiment of the invention. The frame  700  includes a backplane  708  that extends between sidewalls  710 . Although shown as a solid sheet or plane of material, the backplane  708  may include one or more openings, cut-outs, or voids. In one embodiment, the frame  700  includes only sidewall  710  with substantially no backplane  708 . In another embodiment, the backplane  708  includes sections or portions that are stepped or shifted vertically from one another. In yet another embodiment, the frame  700  includes a plurality of backplanes  708  or has portions wherein a plurality of backplane sheets overlap or are positioned in parallel with one another. 
     For example, in one embodiment, a backplane section acts as a support panel  702  that overlaps and/or is positioned substantially in parallel with the backplane  708 , both of which are portions of the frame  700 . The support panel  702  may also provide support for a flexible circuit such as flexible circuit  622  of  FIG. 6 . In another embodiment, the support panel  704  may include arms  714  that are attached to the frame  700 . The support panel  704  may provide support for and be integrated with a flexible circuit. The arms  714  may be formed by folding portion of the support panel  702  such that the arms extend orthagonally from the plane of the support panel  702 . The arms  714  may be attached to the frame  700  using at least one of a mechanical connection, an adhesive, welding, or other attachment means. In yet another embodiment, the support panel  706  may include an arm  716 . The support panel  706  may be integrated with and/or support a flexible circuit and/or any related components. In a further embodiment, a multilayered frame  700  provides increased firmness and structural integrity for a media device and its various components. 
       FIGS. 8A-8C  show a perspective views of support panels  800 ,  802 , and  804  for a flexible circuit according to an illustrative embodiment of the invention. The support panel  800  includes arms  806  and  808 . The support panel  802  includes arms  810  and  820 . The support panel  804  includes arms  822  and  824 . Each of the type of arms  806 ,  810 , and  822  may be configured to enable mechanical attachment of the support panels  800 ,  802 , and  804  respectively to a frame, housing, flexible circuit, and/or other structure within a media device. The support panels  800 ,  802 , and/or  804  may include a metal such as, without limitation, steel. The support panels may be formed by machining, cutting, rolling, punching, stamping, and/or any like metal working process. 
       FIG. 9  shows a transverse view of a flex assembly  900  including flexible circuit  902  according to an illustrative embodiment of the invention. The flex assembly  900  includes a connector  904 , components  906 , an LED  908 , a temporary support panel  910 , driver circuits  912 , acoustic source mounting section  914 , and an extension section  916 . In one embodiment, the connector  904  provides a mechanical connection of the flex assembly  900  to a circuit board such as circuit board  608  of  FIG. 6 . The connector  904  also enables an electrical connection from the circuit board  608  to the components  906 , LED  908 , and an acoustic source that will be mounted to the mounting section  914 . 
     The extension section  916  of the flexible circuit  902  may assume any one of a variety of shapes to enable flexible positioning of, for example, the components  906  at any desired location within a media device housing. For example, without limitation, the extension section may be short, elongated, curved, stepped, folded, multi-folded, multi-stepped, or configured as required to position one or more of the components  906  in a desired position within a media device housing. In one embodiment, the temporary support panel  910  includes at least one of a polymer and a metal to provide support for the flexible circuit  902  prior to installation within a media device, prior to integration with a frame, or during pre-assembly transport. In one embodiment, the temporary support panel  910  is replaced with a permanent support such as support panel  800  of  FIG. 8A . The components  906  may include a proximity sensor emitter  626 , a proximity sensor receiver  628 , an ambient light sensor  630 , a LED  638 , and any other component mounted to the flexible circuit  902 . 
       FIG. 10  shows a transverse view of a flex assembly  1000  including a flexible circuit  1002  having support panels  1004 ,  1006 , and  1008  according to an illustrative embodiment of the invention. The flex assembly  1000  includes a connector  1010 , components  1012 , an LED  1014 , driver circuits  1016 , acoustic source mounting section  1018 , and an extension section  1020 . In one embodiment, the various elements of the flex assembly  1000  function in a similar manner as the elements described with respect to  FIG. 9 . 
     In one embodiment, the support panel  1004  is the same as support panel  804  of  FIG. 8C , the support panel  1006  is the same as support panel  802  of  FIG. 8 , and the support panel  1008  is the same as support panel  800  of  FIG. 8 . In another embodiment, the flexible circuit  1002  is folded at location  1022  such that a first portion  1024  is adjacent to a first surface of the support panel  1008  and a second portion  1026  is adjacent to a second surface of the support panel  1008 . By folding the flexible circuit  1002  around the support panel  1008 , the support panel  1008  provides rigid support for the flexible circuit  1002  and the components mounted to the circuit  1002 . Also, by mounting multiple elements such as components  1012  on the first portion  1024  and driver circuits  1016  on the second portion  1026 , the flexible circuit  1002  provides a compact, yet rigid, structure that is capable of withstanding various physical stresses. 
       FIG. 11  shows a top down view of a flex assembly  1100  including a flexible circuit  1102  according to an illustrative embodiment of the invention. The flex assembly  1100  includes a connector  1104 , a connector support panel  1106 , components  1108 , an LED  1110 , driver circuits (not shown), acoustic source mounting section  1112 , and an extension section  1114 . The mounting section  1112  may include one or more contact pads that provide for mounting of an acoustic source. In one embodiment, the connector  1104  provides a mechanical connection of the flex assembly  1100  to a circuit board such as circuit board  608  of  FIG. 6 . The connector  1104  also enables an electrical connection from the circuit board  608  to the components  1108 , LED  1110 , and an acoustic source that is mounted to the mounting section  1112 . 
     The components  1108  may include a proximity sensor emitter  1118 , a proximity sensor receiver  1120 , an ambient light sensor  1122 , the LED  1110 , and any other component mounted to the flexible circuit  1102 . The extension section  1114  of the flexible circuit  1102  may assume any one of a variety of shapes to enable flexible positioning of, for example, the components  1108  at any desired location within a media device housing. In one embodiment, the connector support panel  1106  provides structural support for the connector  1104 . 
       FIG. 12  shows a top down view of a flex assembly  1200  including a flexible circuit  1102  having support panels  1204 ,  1206 , and  1208  according to an illustrative embodiment of the invention. As described with respect to  FIGS. 8 and 10 , the support panels  1204 ,  1206 , and  1208  provide structural support at various portions of the flexible circuit  1202  and provide support for various components that may be integrated with the flexible circuit  1202 . 
       FIG. 13  shows a perspective view of a flex assembly  1300  including the components shown in  FIGS. 11 and 12  along with an acoustic source  1302  according to an illustrative embodiment of the invention. In one embodiment, the acoustic source  1302  includes an acoustic assembly  1304  having components such as at least one of a transducer, a diaphragm, and electrical components. 
       FIG. 14  shows a perspective view of a flex assembly  1402  integrated with a frame  1404  in a media device  1400  according to an illustrative embodiment of the invention. In one embodiment, the frame  1404  includes one or more openings and/or recesses  1406  associated with one or more components that are integrated with the flexible circuit  1408 . For example, the frame  1404  includes openings  1406  for proximity sensor emitter  1118 , proximity sensor receiver  1120 , ambient light sensor  1122 , LED  1110  (not shown), and the acoustic source  1302 . In one embodiment, the flex assembly  1402  and/or one or more of its elements are integrated with the frame  1404  to provide enhanced structural support to the flex assembly  1402  and its elements. 
       FIG. 15  shows another perspective view of a flex assembly  1402  integrated with the frame  1404  of a media device  1500  according to an illustrative embodiment of the invention. With respect to  FIG. 14 ,  FIG. 15  shows the bottom or second side of the frame  1404 . Thus,  FIG. 15  shows the driver integrated circuits  1502  mounted to the flexible circuit  1408 . With respect to  FIG. 14 , the driver circuits  1502  are below the components  1118 ,  1120  and  1122  that are mounted to a folded section of the flexible circuit  1408 . In one embodiment, a folded portion of the flexible circuit  1408  surrounds the support panel  1204  which provides support to the driver circuits  1502  and components  1118 ,  1120 , and  1122 . In another embodiment, the support panel  1206  provides support for the flexible circuit  1408  and the acoustic source  1302 . In a further embodiment, the support panel  1208  provides support for the flexible circuit  1408  and the LED  1110  shown in  FIG. 11 . In certain embodiments, at least one of the support panels  1204 ,  1206 , and  1208  are integrated with the frame  1404 . 
       FIG. 16  shows a sectional view of a portion of the flex assembly  1402  integrated with a frame  1404  of a media device  1600  according to an illustrative embodiment of the invention. In one embodiment, at least one additional layer  1604  is integrated with at least one of the support panel  1204  and the flexible circuit  1408  to provide additional support and/or to adjust the bend radius of the fold of the flexible circuit  1408  at location  1602 . 
       FIG. 17  shows another transverse sectional view of the flex assembly  1402  integrated with the frame  1404  according to an illustrative embodiment of the invention.  FIG. 17  provide another illustration wherein the support panel  1204  is positioned between a first and second portion of the flexible circuit  1408 . 
       FIG. 18  is a flow chart of a process  1800  for manufacturing a media device according to an illustrative embodiment of the invention. The process  1800 , in one embodiment, includes providing a media device housing such as housing  102  of  FIG. 1  (Step  1802 ). Then, attaching a frame such as frame  700  to the housing (Step  1804 ). Also, a support panel such as support panel  1204  is integrated with the frame (Step  1806 ). Then, a flexible circuit such as flexible circuit  1408  is folded adjacent to the support panel to provide enhanced support for the flexible circuit (Step  1808 ). 
     It is understood that the various features, elements, or processes of the foregoing figures and description are interchangeable or combinable to realize or practice the invention describe herein. Those skilled in the art will appreciate that the invention can be practiced by other than the described embodiments, which are presented for purposes of illustration rather than of limitation, and the invention is limited only by the claims which follow.

Metadata:
Filing Date: 20070105
Publication Date: 20100713
Grant Date: 20100713
Priority Date: 20070105
Inventors: DINH RICHARD HUNG MINH
TAN TANG YEW
WANG ERIK L.
HOBSON PHILIP MICHAEL
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/0274", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M2250/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M2250/12", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 39594784