PATENT DOCUMENT

Publication Number: US-9093234-B2
Application Number: US-201213544812-A
Country: US
Kind Code: B2

Title: Assembly of a handheld electronic device

Abstract:
Several mechanical features of an electronic device are provided. In some embodiments, the device may include a bezel coupled to a housing. One or more snaps of the bezel may be operative to engage a cantilever spring of the housing. In some embodiments, the device may include a window that is formed by coupling an outer layer to an inner layer that is larger than the outer layer. In some embodiments, the device may include a chassis for supporting the window. In some embodiments, the device may include a grounding clip for simultaneously grounding the bezel, the housing and a circuit board. In some embodiments, the device may include a switch that includes a button molded into a base using a double shot process. In some embodiments, the device may include a switch supporting bracket that includes a slot operative to receive a pin of the bezel.

Claims:
What is claimed is: 
     
       1. A chassis for supporting a window in an electronic device comprising a housing, the chassis comprising:
 a plate operative to be placed against a back surface of the window, wherein the window rests against a top surface of the plate; 
 at least two posts extending from a bottom surface of the plate, wherein each of the at least two posts has a first portion that is less stiff than a second portion and the first portion is operative to elastically absorb impacts on the window; and 
 at least one compliant member placed between the at least two posts and the housing of the electronic device case, wherein the at least one compliant member is operative to deform in response to a force applied to the window. 
 
     
     
       2. The chassis of  claim 1 , wherein the plate and at least two posts are operative to remain rigid in response to the force applied to the window to distribute the force to the at least one compliant member. 
     
     
       3. The chassis of  claim 1 , wherein the plate is coupled to the window. 
     
     
       4. The chassis of  claim 1 , wherein the plate is formed from a clear material. 
     
     
       5. The chassis of  claim 1 , wherein the plate comprises:
 at least one aperture, wherein a display generated by the electronic device passes through the at least one aperture. 
 
     
     
       6. The chassis of  claim 1 , wherein the plate is operative to support an optical component of the electronic device. 
     
     
       7. The chassis of  claim 1 , wherein the at least two posts are less stiff than the plate. 
     
     
       8. An electronic device, comprising:
 a housing; 
 a window comprising a front surface and a back surface; 
 a chassis comprising:
 a plate, wherein the back surface of the window rests against a top surface of the plate, wherein the plate comprises at least one aperture and display light generated by the electronic device passes through the at least one aperture; and 
 at least two posts extending from a bottom surface of the plate, wherein the at least two posts are coupled to an inner surface of the housing. 
 
 
     
     
       9. The electronic device of  claim 8 , further comprising:
 at least one compliant member placed between the at least two posts and the inner surface of the housing. 
 
     
     
       10. The electronic device of  claim 9 , wherein the at least one compliant member is operative to deform in response to a force applied to the window. 
     
     
       11. The electronic device of  claim 8 , wherein the plate is operative to support a display that produces the display light. 
     
     
       12. The electronic device of  claim 8 , further comprising:
 a component positioned between the bottom surface of the plate and the inner surface of the housing. 
 
     
     
       13. The electronic device of  claim 12 , wherein the component is a battery. 
     
     
       14. The electronic device of  claim 12 , wherein the component is a circuit board.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 12/204,610, filed Sep. 4, 2008 (now U.S. Pat. No. 8,218,306), which claims the benefit of U.S. Provisional Patent Application No. 60/967,575, filed Sep. 4, 2007, both of which are incorporated by reference herein in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention is directed to mechanical features of an electronic device case. 
     SUMMARY OF THE INVENTION 
     An electronic device case constructed from several components is provided. In some embodiments, the electronic device case may include a housing forming the bottom half of the case and a cantilever spring coupled to the inner surface of the housing such that the spring extends towards the opening of the housing, creating a channel between the spring and the housing wall. The spring may include an aperture. The case may also include a bezel having a post extending from the surface of the bezel. The post may include a snap that extends towards the inside of the case, the snap operative to engage the aperture of the spring when the bezel is placed over the housing and the post extends into the channel. 
     In some embodiments, the electronic device case may include an optical component for providing a display, and a window that includes an inner layer coupled to an outer layer, where the inner layer and outer layer are different components that are combined. A portion of the inner layer may extend beyond the outer layer to form a flange that may be used to couple the window to a bezel. The displays provided by the optical component may pass through the inner layer and appear on the outer layer. 
     In some embodiments, the electronic device case may include a chassis for supporting the window. The chassis may include a plate on which the window may rest, and at least two posts extending from the bottom surface of the plate, away from the plate. The posts may be coupled to the housing by a compliant member that is operative to deform in response to a force applied to the window to avoid bending the window. 
     In some embodiments, the electronic device case may include a grounding clip for grounding the bezel, the housing and a circuit board. The grounding clip may include a base and a spring extending from the base, where the spring contacts the housing. The grounding clip may also include a first connector extending from the base that contacts the bezel, and a second connector extending from the base that contacts the circuit board. 
     In some embodiments, the electronic device case may include a switch (e.g., a hold switch) operative to enable or disable an input mechanism. The switch may include a base that includes a first portion and a second portion that have different colors. The limit between the first and second portions may be substantially the middle of the base. The switch may include a button molded substantially in the middle of the base such that each of the first and second portion appear substantially only on one side of the button. 
     In some embodiments, the electronic device case may include a hold switch bracket for supporting the hold switch. The bracket may include a support operative to be coupled to the bezel. A protrusion operative to support the switch such that the switch is retained between the protrusion and the bezel may extend from the support. The bracket may include a slot operative to receive a pin incorporated in the bezel at a first end of the support, and a hole operative to be aligned with a hole in the bezel to receive a fastener at a second end of the support. 
     In some embodiments, the bezel may be manufactured using in part a forging process. The bezel may be formed by first blanking material, for example a sheet of aluminum. Forging operations may then be applied to the material to form the walls, top surface, and corners of the bezel. The material may then be machined to form holes and undercuts in the bezel (e.g., snaps in the bezel wall). Once machined, the material may be tumbled to provide an aesthetically pleasing finish. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the present invention, its nature and various advantages will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, and in which: 
         FIG. 1A  is a front view of an illustrative electronic device case in accordance with one embodiment of the invention; 
         FIG. 1B  is a bottom view of the electronic device case of  FIG. 1A  in accordance with one embodiment of the invention; 
         FIG. 2  is an exploded view of an electronic device case in accordance with one embodiment of the invention; 
         FIG. 3  is a flow chart of an illustrative process for forging a bezel of an electronic device case in accordance with one embodiment of the invention; 
         FIG. 4  is cross-sectional view of an assembled case in accordance with one embodiment of the invention; 
         FIG. 5  is a cross-sectional view of a window mounted in a case in accordance with one embodiment of the invention; 
         FIG. 6  is a cross-sectional view of another window mounted in a case in accordance with one embodiment of the invention; 
         FIG. 7  is a top view of the display of  FIG. 6  in accordance with one embodiment of the invention; 
         FIG. 8  is a cross-sectional view of a mechanism for supporting a window in a case in accordance with one embodiment of the invention 
         FIG. 9  is a cross-sectional view of the mechanism for supporting a window in the case of  FIG. 8  when a force is applied to the mechanism in accordance with one embodiment of the invention; 
         FIG. 10  is a schematic view of a grounding clip for use in an electronic device case in accordance with one embodiment of the invention; 
         FIG. 11  is a schematic view of a grounding clip in accordance with one embodiment of the invention; 
         FIG. 12  is a cross-sectional view of a clip mounted in a case in accordance with one embodiment of the invention; 
         FIG. 13  is a side view of a hold switch in accordance with one embodiment of the invention; 
         FIG. 14  is a top view of a hold switch in accordance with one embodiment of the invention; 
         FIG. 15  is a schematic view of a hold switch mounted in an electronic device case in accordance with one embodiment of the invention; and 
         FIG. 16  is another schematic view of the switch of  FIG. 15  mounted in an electronic device in accordance with one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1A  is a front view of an illustrative electronic device in accordance with one embodiment of the invention. Device  100  may include any suitable type of electronic device, including for example a media player such as an iPod® available by Apple Inc., of Cupertino, Calif., a cellular telephone (e.g., an iPhone® available from Apple Inc.), a personal digital assistant, a desktop computer, a laptop computer, gaming console, set-top box, television system or television system component (e.g., a recording device), or any other suitable electronic device. Electronic device  100  may include window  110 , input mechanism  120 , and bezel  130 . Window  110  may be any suitable screen or display for providing content to a user of the electronic device. For example, window  110  may include a glass, plastic (e.g., PMMA), composite, combinations thereof, or any other suitable material surface by which content may be displayed. In some embodiments, window  110  may include several layers coupled together (e.g., coupled together using an adhesive). 
     Input mechanism  120  may include any suitable input mechanism for providing inputs to the electronic device. For example, input mechanism  120  may include a wheel and several buttons (e.g., a click-wheel). In some embodiments, input mechanism  120  may be incorporated in window  110  as a touch-screen input mechanism/such as that described in U.S. Pat. No. 6,323,846, which is incorporated by reference herein in its entirety. The user interface may emulate a rotary phone or a multi-button keypad, which may be implemented on a touch screen or the combination of a click wheel or other user input device and a screen. A more detailed discussion of such a rotary phone interface may be found, for example, in U.S. patent application publication No. 2007/0152983, published on Jul. 5, 2007, which is incorporated by reference herein in its entirety. 
     Bezel  130  may form the upper outer surface of electronic device  100 . Bezel  130  may include apertures for receiving window  110  and input mechanism  120 , and may include features on the inner surface of bezel  130  for coupling each of window  110  and input mechanism  120  in bezel  130 . In some embodiments, bezel  130  may include additional apertures for accessing connectors and input mechanisms. Bezel  130  may be coupled to housing  160  to form an enclosure (e.g., the case of electronic device  100 ) into which electronic device components may be placed. Bezel  130  may be coupled to housing  160  using any suitable approach, including using snaps as described in more detail below. 
     Bezel  130  may have any suitable shape. For example, bezel  130  may include a substantially flat top surface  131  from which vertical walls  132  may extend. Bezel  130  may include a curved edge along the interface between top surface  131  and vertical walls  132  having any suitable curvature, including for example a highly elongated sloping curve. The curvature of the edges may be selected based on any suitable criteria, including for example aesthetics or industrial design considerations.  FIG. 1B  is a bottom view of the electronic device case of  FIG. 1A  in accordance with one embodiment of the invention. As shown in  FIG. 1B , bezel  130  may include apertures for accessing hold switch  140 , connector  142 , and jack plug  144 . 
       FIG. 2  is an exploded view of an electronic device in accordance with one embodiment of the invention. Electronic device  200  may include bezel  230 , input mechanism  220 , and window  210 , which may include some or all of the features described above in connection with electronic device  100  ( FIG. 1 ). In some embodiments, input mechanism  220  may be include outer ring  221  and inner button  222  (e.g., to form a click-wheel). 
     Electronic device  200  may include chassis  240 , which may be operative to support window  210  when electronic device  200  is assembled. Chassis  240 , as described below in more detail, may include additional space below chassis  240  to house battery  242 . In some embodiments, chassis  240  may extend beyond the periphery of window  210  and support circuit board  244 , which may include the control circuitry, memory, and other components used to operate electronic device  200 . 
     Electronic device  200  may include hold switch assembly  250 , which may include a hold switch and a bracket, as described below in more detail. Electronic device  200  may include housing  260 , which may be coupled to bezel  230  to form the outer surface of electronic device  200 . Housing  260  may be constructed from any suitable material, and using any suitable approach. For example, housing  260  may be formed from aluminum or stainless steel (e.g., 304 series stainless steel), which may be then be finished (e.g., polished or brushed) to provide an aesthetically pleasing design. In some embodiments, electronic device  200  may also include clip  252 , which may be operative to ground several components of the electronic device. For example, clip  252  may be operative to ground bezel  230 , circuit board  242 , and housing  260 , as described in more detail below. 
     Bezel  230  may be constructed from any suitable material and using any suitable approach. For example, bezel  230  may be constructed from a metal (e.g., steel, aluminum, or titanium), a composite material, plastic, or any other suitable material. In one particular implementation, bezel  230  may be constructed from aluminum and housing  260  may be formed from steel. In some embodiments, bezel  230  may be at least partially constructed using a forging process. For example, 60% of the final shape of bezel  230  may be achieved using a forging process, and the remaining 40% may be achieved using a machining process. 
     A forging process may include, for example, shaping metal using localized compressive forces. The forging process may be done at any temperature, including at room temperature or near room temperature (e.g., cold forging), at a high temperature, which makes metal easier to shape and less likely to fracture (e.g., hot forging), or at intermediate temperature between room temperature and hot forging temperatures (e.g., warm forging). Using a forging process, the thickness of the material may be controlled at different points along a surface (e.g., unlike stamping). For example, a shape may be formed using a series of presses, each press having a different shape, thus allowing for complex geometries (e.g., defined by the different presses) while providing structure and variation in wall thickness (e.g., unlike using a die cast). Forging may also provide a smooth surface, which can eliminate the need for additional finishing processes (e.g., unlike machining). 
       FIG. 3  is a flow chart of an illustrative process for forging a bezel of an electronic device case in accordance with one embodiment of the invention. Process  300  may begin at step  302 . At step  304 , the material used to create the bezel may be blanked. For example, a piece of stock aluminum or steel may be stamped or punched out (e.g., blank a piece of aluminum from which the bezel will be formed). The blanked material may have initial dimensions that exceed the final dimensions of the bezel. The initial material may have any suitable thickness, including for example a thickness in the range of 0.5 to 4.5 mm (e.g., 2.5 mm). At step  306 , vertical walls may be forged in the blanked material (e.g., vertical wall  132 ,  FIG. 1 ). For example, the material may be placed in a die and forged to push vertical walls of the bezel inward to reduce the height of the walls and to increase the width of the walls. 
     At step  308 , the top surface of the bezel may be forged (e.g., top surface  131 ,  FIG. 1 ). For example, the material may be placed in a die (e.g., the same die or a different die as in step  306 ) and forged to shape the curvature of the top surface (e.g., to forge a gradual shape with a gentle curve). At step  310 , the internal corners and other internal features of the bezel may be forged. For example, the material may be placed in a die and forged with a higher pressure than at step  306  to forge the internal corners and features of the bezel. Each of steps  306 ,  308  and  310  may be repeated as necessary with different dies and different forging pressures until the shape of the bezel matches the desired final shape. 
     At step  312 , the features that cannot be manufactured using forging may be machined in the bezel. For example, the holes for the window (e.g., window  110 ,  FIG. 1 ) and the input mechanism (e.g., input mechanism  120 ,  FIG. 1 ) may be machined. As another example, the undercuts in the bezel wall (e.g., snaps  434 ,  FIG. 4 ) may be machined from the forged bezel. As still another example, screw holes for coupling electronic device components to the bezel may be tapped. At step  314 , the machined bezel may be tumbled to polish the surface of the bezel. The bezel may be tumbled with any suitable material (e.g., ceramic balls or walnut shells) at any suitable speed to polish the surface of the bezel. Process  300  may then end at step  316 . 
     To assemble the electronic device, the bezel may include a snap operative to engage a component coupled to the housing.  FIG. 4  is cross-sectional view of an assembled electronic device in accordance with one embodiment of the invention. Electronic device  400  may include housing  410  and bezel  430 . Bezel  430  may engage housing  410  using snap  434  extending from post  432 . In some embodiments, the position and orientation of post  432  and snap  434  may be constrained by the shape and dimensions of electronic device  400 . For example, housing  410  may have any suitable curvature  412 , including for example a large radius or spline, thus providing a longer curved back surface for electronic device  400 . In addition, electronic device  400  may be thin (e.g., 6.5 mm). The combination of the curvature of housing  410  and the thickness of electronic device  400  may limit the space available between wall or post  432  and inner surface  414  of housing  410  when electronic device  400  is assembled. To accommodate the reduced space, snap  434  of bezel  430  may not extend out towards inner surface  414 , but may instead extend in away from inner surface  414 . 
     Electronic device  400  may include spring  450  operative to engage snap  434  when electronic device  400  is assembled. Spring  450  may be any suitable spring type, including for example a cantilever spring. Spring  450  may be formed from any suitable material that allows spring  450  to be elastically deformed when bezel  430  is inserted into housing  410  (e.g., to accommodate for snap  434  as it passes into aperture  452 ). For example, spring  450  may be formed from a material with a high modulus of elasticity, such as metal (e.g., aluminum or steel), plastic, a composite material, or any other suitable material. In some embodiments, spring  450  may include at least one portion that is responsive to a magnetic force in the presence of a magnetic field (e.g., to release bezel  430  when a magnet is approached to electronic device  400 ). 
     Spring  450  may have any suitable shape. In some embodiments, spring  450  may have a U-shaped or J-shaped cross-section defining a channel in which post  432  may extend when electronic device  400  is assembled. Outer wall  454  of spring  450  may be coupled to housing  410 , and inner wall  456  of spring  450  may extend away from inner surface  414  of housing  410  such that post  432  may extend between outer wall  454  and inner wall  456 . Outer wall  454  may be coupled to housing  410  using any suitable approach. For example, spring  450  may be mechanically coupled to housing  410  (e.g., using one or more snaps and apertures), coupled using hook and loop material (e.g., Velcro®), an adhesive, or any other suitable approach. In some embodiments, outer wall  454  of spring  450  may be welded to inner surface  414  of housing  410  (e.g., if at least a portion of spring  450  is metallic and may be welded). 
     Inner wall  456  may include aperture  452  operative to receive snap  434  when bezel  430  engages spring  450 . Aperture  452  may include any suitable feature for receiving and engaging snap  434 . For example, aperture  452  and snap  434  may include opposing features (e.g., flat surfaces operative to press against each other) operative to maintain bezel  430  engaged with spring  450 . As another example, snap  434  may extend beyond the outer edge of spring  450  to more securely engage aperture  452 . 
     By including snaps  434  that extend into electronic device  400 , bezel  430  may engage housing  410  more securely than if snaps  434  extended towards inner surface  414  of housing  410 . For example, during a drop event or when electronic device  400  receives an impact (e.g., housing  410  of electronic device  400  is hit), a force may be applied to post  432  that causes post  432  to move away from inner surface  414  and towards inner wall  456  of spring  450 . By moving towards inner wall  456 , snap  434  further engages aperture  452  and reduces the chance that bezel  430  will disengage spring  450  and housing  410  during a drop event. If snap  434  instead were to extend towards inner surface  414  and engage spring  450  between post  432  and housing  410 , a drop event would cause post  432  and snap  434  to move away from spring  450  and aperture  452 , thus increasing the chance that bezel  430  disengages housing  410 . 
     The electronic device of the invention may include a window for providing displays to the user. The window may be formed from any suitable material, including for example plastic (e.g., polymethyl methacrylate, or PMMA) or glass, and may be mounted within the case using any suitable approach.  FIG. 5  is a cross-sectional view of a window mounted in a case in accordance with one embodiment of the invention. Electronic device  500  may include bezel  530  and window  550 . Window  550  may include flange  552  operative to fit below lip  532  of bezel  530  to mount window  550  in the case. When electronic device  500  is assembled, window  550  may be held in place by the contact between lip  532  and flange  552 . In some embodiments, lip  532  and flange  552  may be coupled using any suitable approach, including for example an adhesive, a gasket (e.g., in a press-fit), a fastener (e.g., one or more screws), or any other suitable approach. 
     Because of flange  552 , window  550  may experience significant stresses at point  554 , where flange  552  initially extends beyond the displayed portion of window  550 . In some embodiments, the stresses may be so significant as to prevent window  550  from being constructed from brittle materials, such as glass. Instead, it may be necessary to construct window  550  with flange  552  from plastic (e.g., PMMA). For example, flange  552  may be machined into a piece of PMMA. Because glass may have better optical properties and better abrasion resistance than PMMA, however, it may be desirable to provide a glass window with a flange for mounting to the bezel. 
       FIG. 6  is a cross-sectional view of another window mounted in a case in accordance with one embodiment of the invention. Electronic device  600  may include bezel  630  and window  648 . As with electronic device  500  ( FIG. 5 ), bezel  630  may include lip  632  under which a portion of window  648  may fit to mount display  650  to bezel  630 . Window  648  may include an outer layer  650  and inner layer  656 . Outer layer  650  may include outer surface  651  that is exposed to the user of electronic device  600 , and inner surface  652  which may be coupled to inner layer  656 . Inner layer  656  may be larger than outer layer  650  such that flanges  655  of inner layer  656  extend beyond the edge of outer layer  650 .  FIG. 7  is a top view of the display of  FIG. 6  in accordance with one embodiment of the invention. As shown in  FIG. 7 , window  648  may include outer layer  650  and inner layer  656 . Outer layer  650  may be smaller than inner layer  656  such that a portion of inner layer  656  extends beyond outer layer  650 , forming flange  655 . Flange  655  may be operative to fit against lip  632  when window  648  is mounted in bezel  630 . In some embodiments, flange  655  may extend entirely around the edge of outer layer  650 , or only around portions of the edge of outer layer  650  (e.g., only around the top and bottom, only around the sides, only around the corners, or in sections around one or more sides or corners). By constructing window  648  from two distinct pieces, the stresses at point  654  (i.e., where flange  655  begins and meets lip  632 ), are not as high in outer layer  650  and thus reduce the risk of outer layer  650  breaking. 
     Outer layer  650  and inner layer  656  may be coupled using any suitable approach, including for example an adhesive placed between outer layer  650  and inner layer  656 , or any other suitable approach. In some embodiments, outer layer  650  and inner layer  656  may be coupled in an manner that does not affect images created by optical components located underneath inner layer  656  (e.g., such that displays are generated underneath inner layer  656 , and pass through inner layer  656  and the coupling mechanism before being displayed in outer layer  650 . In some embodiments, inner layer  656  may include one or more apertures through which generated displays may be projected. For example, inner layer  656  may only be placed around the border of outer layer  650  such that the entire center of outer layer  650  is unobstructed. By maintaining inner layer  656  around the border of outer layer  650 , window  648  may still be coupled to bezel  630  using flanges  655 . A more detailed description of an approach for coupling outer layer  650  and inner layer  656  may be found in commonly owned U.S. Pat. No. 7,966,785, issued on Jun. 28, 2011, incorporated herein in its entirety. In some embodiments, outer layer  650  may be constructed from glass to provide scratch resistance and high quality optical displays, and inner layer  656  may be constructed from PMMA or another plastic to provide resistance to the stresses caused by mounting window  648  to bezel  630 . 
     Window  648  may be coupled to bezel  630  using any suitable approach. In some embodiments, only inner layer  656  may be coupled to bezel  630 , for example by coupling flange  655  to lip  632  using an adhesive, a gasket (e.g., in a press-fit), a fastener (e.g., one or more screws), or any other suitable approach. In some embodiments, outer layer  650  and inner layer  656  may both be coupled to bezel  630 , for example by coupling flange  655  to lip  632  (e.g., using an approach described above) and coupling outer layer  650  to the sides of bezel  630  (e.g., using an adhesive, or a gasket in a press-fit). 
     In some embodiments, in addition to supporting the window using flanges  655  coupled to bezel  630 , the electronic device may include an additional mechanism for supporting the window.  FIG. 8  is a cross-sectional view of a mechanism for supporting a window in an electronic device in accordance with one embodiment of the invention. Electronic device  800  may include housing  810 , bezel  830 , and window  850 . Window  850  may be supported around its perimeter by flanges coupled to bezel  830  and by a supporting mechanism placed in contact with inner surface  852  of window  850 . 
     One approach for supporting inner surface  852  of window  850  may be to provide a solid support between inner surface  852  and inner surface  812  of housing  810 . Such an approach, however, may lead to significant lost space between window  850  and housing  810 . To avoid losing the space between window  850  and housing  810  while providing support to inner surface  852  of window  850 , the electronic device may include chassis  860  operative to support window  850  while maintaining space available for additional components between chassis  860  and housing  810 . 
     Chassis  860  may include plate  862  and posts  864 . Plate  862  may be operative to support some, all, or substantially all of inner surface  852  of window  850  to prevent window  850  from bending in response to forces applied to outer surface  851  (e.g., due to an impact, or from a user&#39;s finger). In some embodiments, plate  862  may be operative to support additional components of the electronic device (e.g., a circuit board). Plate  862  may therefore have any suitable shape, including a shape that substantially matches the shape of window  850 . Plate  862  may have any suitable stiffness, including for example a high stiffness against bending. Plate  862  may be formed from any material with having a suitable stiffness, including for example a metal, a plastic, or a composite material. In some embodiments, plate  862  may be coupled to window  850  to further increase the window&#39;s resistance to bending (e.g., using an adhesive). 
     In some embodiments, plate  862  may be positioned between optical components providing displays to window  850 . To avoid interfering with the generated displays, plate  862  may be formed from a clear material, or may include one or more apertures through which the generated displays may pass. In some embodiments, plate  862  may instead support both the optical components generating the displays and window  850 . In such embodiments, plate  862  may be constructed from any suitable material without accounting for optical considerations. 
     Plate  862  may be held a distance from inner surface  812  of housing  810  by posts  864 . Chassis  860  may include any suitable number of posts  864 , and any suitable shape for posts  864 . For example, chassis  860  may include several discreet posts around portions of plate  862  (e.g., at the corners of plate  862 ). As another example, chassis  860  may include one or more discreet or elongated posts  864  along two or more specific portions of plate  862  (e.g., chassis  860  may include four posts  864  forming walls around the periphery plate  862 ). Posts  864  may be constructed from any suitable stiff material operative to resist buckling due to forces exerted on window  850  and transmitted by plate  862 . In some embodiments, posts  864  may be less stiff than plate  862  such that, in the event that a large force is applied to window  850 , posts  864  bend before plate  862  buckles and window  850  bends (and possibly cracks, for example if window  850  is glass). In some embodiments, electronic device  800  may include one or more electronic device components between plate  862  and housing  810  (e.g., a battery). 
     Posts  864  may be coupled to inner surface  812  of housing  810  using any suitable approach. In some embodiments, posts  864  may be directly coupled to inner surface  812 . For example, posts  864  may be coupled to housing  810  using an adhesive, a fastener (e.g., a screw), hook and fastener material (e.g., Velcro), mechanical features of the posts and housing (e.g., male and female counterpart elements), or any other suitable approach. In some embodiments, a portion of each post  864  (e.g., the bottom portion) may be less stiff than the rest of post  864  to elastically absorb smaller (and more frequent) impacts on window  850  without affecting the structural integrity of the remaining portions of posts  864  and plate  862 . 
     In some embodiments, posts  864  may be coupled to housing  810  by the intermediary of compliant material  866 . Compliant material  866  may be operative to deform in response to forces applied to window  850  so that chassis  860  may not deform.  FIG. 9  is a cross-sectional view of the mechanism for supporting a window in the case of  FIG. 8  when a force is applied to the mechanism in accordance with one embodiment of the invention. When force  870  is applied to window  850  (e.g., a user presses on window  850  with a finger), window  850  and chassis  860  may rigidly be displaced to transfer force  870  to compliant material  866 , which may in turn deform to accommodate force  870 . Compliant material  866  may be selected and constructed such that, in its deformed state, plate  862  does not apply pressure to electronic device components located between housing  810  and chassis  860 . 
     Compliant material  866  may be constructed from any suitable material. For example, compliant material  866  may be constructed from a soft plastic, synthetic material, foam, sponge, or any other suitable material. Compliant material  866  may be placed at the end of some or all of posts  864 . In some embodiments, compliant material  866  may be placed between posts  864  (e.g., as a strip of a foam that follows the edge of plate  862  if chassis  860  includes several distinct posts  864 ). 
     The electronic device components placed within the case may be grounded using any suitable approach. In some embodiments, several grounding components may be used to ground each of the electronic device components of the electronic device (e.g., a circuit board, a bezel, a housing, and a gimbal plate for an input mechanism). In other embodiments, a single grounding component may be used for all of the electronic device components, which may allow for a compact component that is easy to manufacture.  FIG. 10  is a schematic view of a grounding clip for use in an electronic device case in accordance with one embodiment of the invention. Electronic device  1000  may include housing  1010 , bezel  1030 , circuit board  1035  and grounding clip  1040 . Clip  1040  may include a number of portions operative to contact each of housing  1010 , bezel  1030 , circuit board  1035 , and fasteners  1050  and  1052 , including platforms  1042  and  1044 . For example, fastener  1050  may couple platform  1042  to bezel  1030  and fastener  1052  may couple platform  1044  to circuit board  1035 .  FIG. 11  is a schematic view of a grounding clip in accordance with one embodiment of the invention. Grounding clip  1100  may include base  1110 . Base  1110  may provide a platform from which different components of clip  1100  extend to come into contact with electronic device components (e.g., components identified in  FIG. 10 ). 
     Clip  1100  may include one or more springs  1120  operative to contact the case housing (e.g., housing  1010 ,  FIG. 10 ) when clip  1100  is mounted in the case. Springs  1120  may be any suitable type of spring, including for example a leaf spring, helical spring, spiral spring, cantilever spring, or any other suitable spring. In the example of  FIG. 11 , spring  1120  may include a cantilever spring coupled to base  1110  along line  1122 . Spring  1120  may include curved strip  1124  that extends from base  1110  towards the ultimate position of the case housing. The length of strip  1124  may be selected such that tip  1126  of strip  1124  is in contact with the housing when clip  1100  is mounted in the case and strip  1124  is forced to bend elastically to accommodate the proximity of the housing, as described in more detail in  FIG. 12 . 
     Clip  1100  may include first connector  1130  operative to couple clip  1100  to the bezel (e.g., bezel  1030 ,  FIG. 10 ). Connector  1130  may include platform  1134 , which may be in a different plane than base  1110 , and connected to base  1110  via wall  1132 . In some embodiments, platform  1134  may be co-planar or substantially co-planar with base  1110 , and wall  1132  may be orthogonal to or substantially orthogonal to at least one of base  1110  and platform  1134 . Wall  1132  may be at a first end of base  1110  such that, as seen from the top, platform  1134  appears to extend base  1110 . In some embodiments, base  1110 , wall  1132  and platform  1134  may have substantially the same width, or platform  1134  may be tapered to accommodate the bezel. 
     Platform  1134  may be coupled to the bezel using any suitable approach. For example, platform  1134  may be coupled to the bezel by welding, soldering, a mechanical fastener (e.g., a screw), tape, an adhesive, or any other suitable approach that maintains the electrical connectivity between platform  1134  and the bezel. In some embodiments, platform  1134  may include hole  1136  operative to receive a mechanical fastener (e.g., a screw). As shown in  FIG. 10 , platform  1042  may be placed below protrusion  1032  of bezel  1030 . To maintain platform  1042  in contact with protrusion  1032  to ground bezel  1030 , fastener  1050  may be passed through protrusion  1032  and platform  1042  (e.g., through hole  1136 ,  FIG. 11 ). In some embodiments, fastener  1050  may be constructed from an electrically conductive material to enhance the transfer of current from platform  1042  to protrusion  1032  (e.g., a copper screw). 
     Clip  1100  may include second connector  1140  operative to couple clip  1100  to the circuit board (e.g., circuit board  1035 ,  FIG. 10 ). Connector  1140  may include platform  1144 , which may be in a different plane than base  1110 , and connected to base  1110  via wall  1142 . In some embodiments, platform  1144  may be co-planar or substantially co-planar with base  1110 , and wall  1142  may be orthogonal to or substantially orthogonal to at least one of base  1110  and platform  1144 . Wall  1142  may be at a first end of base  1110  such that, as seen from the top, platform  1144  appears to extend base  1110 . In some embodiments, base  1110 , wall  1142  and platform  1144  may have substantially the same width, or platform  1144  may be tapered to accommodate the bezel. 
     Platform  1144  may be coupled to the bezel using any suitable approach. For example, platform  1144  may be coupled to the bezel by welding, soldering, a mechanical fastener (e.g., a screw), tape, an adhesive, or any other suitable approach that maintains the electrical connectivity between platform  1144  and the bezel. In some embodiments, platform  1144  may include hole  1146  operative to receive a mechanical fastener (e.g., a screw). As shown in  FIG. 10 , platform  1044  may be placed above circuit board  1035 . To maintain platform  1044  in contact with circuit board  1035 , fastener  1052  may be passed through circuit board  1035  and platform  1044  (e.g., through hole  1146 ,  FIG. 11 ). In some embodiments, fastener  1052  may be constructed from an electrically conductive material to enhance the transfer of current from platform  1044  to circuit board  1035  (e.g., a copper screw). 
       FIG. 12  is a cross-sectional view of a clip such as the clip of  FIG. 11  mounted in an electronic device in accordance with one embodiment of the invention. Electronic device  1200  may include housing  1210  and bezel  1230 . Clip  1260  may include some or all of the features of clip  1100  ( FIG. 11 ). Clip  1260  may be placed within electronic device  1200  such that strip  1264  extends away from base  1262  towards housing  1210 . As shown in  FIG. 12 , strip  1264  may be constructed such that it is longer than necessary to reach inner surface  1212  of housing  1210  (e.g., tip  1266  of strip  1264  extends beyond inner surface  1212 ). When assembled, strip  1264  may be forced to bend such that tip  1266  remains in contact with inner surface  1212  (e.g., and does not pass through housing  1210 ). The elastic deformation of strip  1264  caused by forcing strip  1264  to bend create an opposing may maintain clip  1260  in contact with housing  1210 , and thus continue to ground housing  1210  in the event of impacts or other events that could cause strip  1264  to be displaced. 
     Clip  1100  (and clip  1260 ) may be formed from any material suitable from grounding electronic device components. For example, clip  1100  may be formed from a metal, a semi-conductor, a composite material, or any other suitable material with sufficient electrical conductivity. In some embodiments, clip  1100  may be copper having a thickness of substantially 0.1 mm. Clip  1100  may be manufactured using any suitable approach, including for example forging, molding, casting, forming, stamping, machining, combinations of these, or any other suitable approach. In some embodiments, additional operations may be performed on clip  1100  once the shape of clip  1100  has been set to improve electrical conductivity or to make clip  1100  more aesthetically pleasing (e.g., a polishing process or a plating process). 
     The electronic device case may have a number of input mechanisms. In some embodiments, the electronic device case may include a hold switch (e.g., hold switch  140 ,  FIG. 1B ). The hold switch may be operative to disable another input mechanism (e.g., input mechanism  120 ,  FIG. 1A ) to avoid undesired inputs, for example when the electronic device is in a user&#39;s pocket. When the user wishes to provide an input using the other input mechanism, the user may move the hold switch from its initial position (e.g., “hold”) to a second position (e.g., “active”). 
       FIG. 13  is a side view of a hold switch in accordance with one embodiment of the invention, and  FIG. 14  is a top view of a hold switch in accordance with one embodiment of the invention. Switch  1300  may include button  1302  that is captured by base  1310 . Button  1302  may be any suitable button for extending beyond the outer surface of base  1310  (e.g., for extending into a channel of the bezel which base  1310  remains under the surface of the bezel). Button  1302  may be constructed from any suitable material, including for example, plastic, composite materials, metal (e.g., aluminum), ceramics, or any other suitable material. In some embodiments, button  1302  and base  1310  may be constructed from different materials (e.g., for aesthetic purposes, or to more clearly differentiate button  1302  from base  1310 ). Button  1302  may have any suitable shape, including for example cylindrical. 
     Button  1302  may be captured by base  1310  using any suitable approach. For example, base  1310  may include an opening into which button  1302  is press fit. As another example, button  1302  may be coupled to base  1310  (e.g., using an adhesive, tape, or a mechanical fastener). As still another example, button  1302  may be molded into base  1310  during the manufacturing process. Base  1310  may include first portion  1312  manufactured from a first color (e.g., orange), and second portion  1320  manufactured from a second color (e.g., white). When switch  1310  is in a first position, only first portion  1312  and button  1302  may be visible through the bezel, indicating to the user that switch  1310  is in its first position (e.g., indicating that the click-wheel is locked). When switch  1310  is in a second position, only second portion  1320  and button  1302  may be visible through the bezel, indicating to the user that switch  1310  is in its second position (e.g., indicating that the click-wheel is unlocked). 
     To manufacture base  1310  from materials having two colors (e.g., from two different materials), base  1310  may be constructed using a double shot process. First, first portion  1312  may be molded using a first material (e.g., a first plastic having a first color). In some embodiments, button  1302  may begin to be molded into first portion  1312  to form switch  1300 . Once first portion  1312  has been molded, second portion  1320  may be molded around first portion  1312  such that first portion  1312  is captured by the material forming second portion  1320  (e.g., a second plastic having a second color). Button  1302  may be completely captured by base  1310  when second portion  1320  is molded around first portion  1312 . In some embodiments, second portion  1320  may be molded before first portion  1312 . 
     First portion  1312  may be defined, at the end opposite button  1302 , by curved surface  1314 . Curved surface  1314  may be defined by a spline  1316 . In some embodiments, curved surface  1314  may be constructed to match the curvature of the inner surface of the bezel, against which the second portion may abut when switch  1300  is moved. In some embodiments, the top surfaces of first portion  1312  and second portion  1320  may be curved surfaces, where the curvature of the surfaces is defined by a spline. The spline may be selected to match the curvature of the inner surface of the bezel under which switch  1300  is placed (e.g., as shown in  FIG. 15 ). 
     Base  1310  may include prongs  1330  and  1332  extending from base  1310  away from button  1302  (e.g., hidden from the user&#39;s view). Prongs  1330  and  1332  may be operative to engage a mechanism with the electronic device to change the state of the electronic device when switch  1300 , and thus prongs  1330  and  1332  are displaced. For example, a mechanism may be placed between prongs  1330  and  1332  such that, as switch  1300  moves, one of prongs  1330  and  1332  may move the mechanism to follow the movement of switch  1300 . 
     Switch  1300  may be held in position in the bezel using any suitable approach.  FIG. 15  is a schematic view of a hold switch mounted in an electronic device case in accordance with one embodiment of the invention.  FIG. 16  is another schematic view of the switch of  FIG. 15  mounted in an electronic device in accordance with one embodiment of the invention. Case  1500  may include bezel  1530 , which may include channel  1532  through which button  1512  of switch  1510  may extend. Channel  1532  may be constructed such that the width of channel  1532  is substantially that of button  1512 , and the length of channel  1532  is substantially that of one of first portion  1514  and second portion  1516  (e.g., such that only one of first portion  1514  and second portion  1516  are visible through channel  1532  when switch  1510  moves). Button  1512  may be constructed such that button  1512  partially extends beyond the outer surface of bezel  1530  (e.g., so that the user may actuate switch  1510  by moving button  1512 ). 
     Switch  1510  may be held in channel  1532  using any suitable approach. In some embodiments, switch  1510  may be held in position by bracket  1540 , and may be biased forward (e.g., into channel  1532 ). Bracket  1540  may include protrusion  1542  operative to support switch  1510 . For example, the lower surface of base  1511  may rest on protrusion  1542 , thus holding switch  1510  between bezel  1530  and bracket  1540 . By supporting substantially the entire length of switch  1510  with a protrusion  1542 , forces applied to switch  1510  may be distributed to bezel  1530  and may reduce the risk that switch  1510  or bracket  1540  fails. Protrusion  1542  may include slot  1544  for receiving prongs  1518  and  1519  of switch  1510 . The length of slot  1544  may be selected such that one of prongs  1518  and  1519  abuts against the end of slot  1544  when button  1512  abuts against one of the ends of channel  1532 . 
     Bracket  1540  may be mounted to bezel  1530  using any suitable approach. In some embodiments, bracket  1540  may include support  1550  from which protrusion  1542  extends. Support  1550  may be placed against the surface of bezel  1530  and coupled to bezel  1530  using any suitable approach. In some embodiments, support  1550  may be coupled to the surface of bezel  1530  using an adhesive, tape, a frictional fit (e.g., a snap fit), a mechanical fastener, or any other suitable approach. In some embodiments, support  1550  may include features on its lower surface operative to match features of the surface of bezel  1530  (e.g., ridges in bezel  1530  are matched with channels in support  1550 ). In some embodiments, support  1550  may include features to support components of the electronic device (e.g., a circuit board). 
     In some embodiments, support  1550  may be coupled to bezel  1530  using a pin and slot and a mechanical fastener. Support  1550  may include slot  1552  operative to receive pin  1534  of bezel  1530 . Slot  1552  may be located at one end of support  1550  to serve as a first anchor for support  1550 . Support  1550  may include hole  1554  at an opposite end of support  1550  for receiving a mechanical fastener (e.g., a screw). By coupling opposite ends of support  1550  to bezel  1530  using slot  1552  and hole  1554 , bracket  1540  may be securely coupled to bezel  1530 , and thus maintain switch  1510  securely in channel  1532  of bezel  1530 . 
     To mount bracket  1540  in bezel  1530 , support  1550  may be placed in bezel  1530  such that pin  1534  extends into slot  1552 . Bracket  1540  may then be rotated until hole  1554  is aligned with a corresponding hole in bezel  1530  so that fastener  1560  (e.g., a screw) may be inserted in hole  1554  and the corresponding hole in bezel  1530 . By controlling the amount by which bracket  1540  is rotated around pin  1534 , the amount by which button  1512  extends out of bezel  1530  may be controlled. In addition, the space made available for switch  1510  to slide between bracket  1540  and bezel  1530  may be controlled by the rotation of bracket  1540 , and thus the looseness or tightness of the sliding of switch  1510  may be controlled. By using pin  1532  and slot  1552  at one end of support  1550  (e.g., instead of another fastener) to couple bracket  1540  to bezel  1530 , bracket  1540  may retain a low profile and leave more space available in case  1500  for other electronic device components (e.g., a circuit board). 
     The above described embodiments of the invention are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow.

Metadata:
Filing Date: 20120709
Publication Date: 20150728
Grant Date: 20150728
Priority Date: 20070904
Inventors: LYNCH STEPHEN BRIAN
MOOLSINTONG PINIDA JAN
LIM LENG
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K5/15", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/15", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H9/0207", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H9/0207", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49995", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K5/0013", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H15/10", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2223/034", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49995", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H15/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/10", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K7/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H9/0207", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0217", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49995", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H15/10", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 40407104