PATENT DOCUMENT

Publication Number: US-8265329-B2
Application Number: US-24051908-A
Country: US
Kind Code: B2

Title: Compact housing for portable electronic device with internal speaker

Abstract:
Improved approaches for providing a speaker within a housing of a portable electronic device are disclosed. The housing of the portable electronic device can be compact, such as a low profile housing. In one embodiment, an acoustic chamber for a speaker can be formed internal to a housing for a portable electronic device using non-dedicated space. In another embodiment, irregular surfaces can be sealed so that an acoustic chamber for a speaker can be formed internal to a housing for a portable electronic device.

Claims:
1. A portable electronic device, comprising
 a printed circuit board; 
 electrical components mounted on said printed circuit board; 
 an EMI shielding structure attached to said printed circuit board, said EMI shielding structure be provided over one of more of said electrical components; 
 a speaker attached to said EMI shielding structure; and 
 a form-in-place seal used to at least in part form an acoustic chamber for said speaker, 
 wherein said EMI shielding structure comprises a EMI shielding can, and wherein said EMI shielding can includes one or more first openings in a top surface, and includes one or more second openings in at least one side surface, and 
 wherein at least one of the one or more second openings is substantially sealed with said form-in-place seal. 
 
     
     
       2. A portable electronic device as recited in  claim 1 , wherein the acoustic chamber includes a substantially isolated volume of air. 
     
     
       3. A portable electronic device as recited in  claim 1 , wherein one or more of said electrical components are provided within the acoustic chamber. 
     
     
       4. A portable electronic device as recited in  claim 1 ,
 wherein said portable electronic device further comprises a housing, and 
 wherein said housing includes at least said printed circuit board, said electrical components, said EMI shielding structure, said speaker and said form-in-place seal. 
 
     
     
       5. A portable electronic device as recited in  claim 4 , wherein said speaker is configured within said housing of said portable electronic device to have a front volume and a back volume, with the back volume being isolated from the front volume. 
     
     
       6. A portable electronic device as recited in  claim 4 , wherein said form-in-place seal is arranged to isolate at least a part of the back volume from the front volume. 
     
     
       7. A portable electronic device as recited in  claim 5 , wherein said back volume is greater than the front volume. 
     
     
       8. A portable electronic device as recited in  claim 1 , wherein said form-in-place seal has a low viscosity when placed within said housing and is thereafter cured to a higher viscosity. 
     
     
       9. A portable electronic device as recited in  claim 1 , wherein said speaker is a flat speaker. 
     
     
       10. A portable electronic device as recited in  claim 1 , wherein said speaker is attached on the top surface of said EMI shielding can such that the one or more first openings are covered by said speaker. 
     
     
       11. A portable electronic device as recited in  claim 1 , wherein an interface between the front volume and the back volume is provided in part by said EMI shielding can. 
     
     
       12. A portable electronic device as recited in  claim 1 , wherein said portable electronic device further comprises at least one gasket to assist with forming the acoustic chamber for said speaker. 
     
     
       13. A portable electronic device as recited in  claim 12 , wherein said speaker is configured within said portable electronic device to have a front volume and a back volume, with the back volume being isolated from the front volume. 
     
     
       14. A portable electronic device as recited in  claim 13 , wherein an interface between the front volume and the back volume is provided by said EMI shielding structure, said at least one gasket and said form-in-place seal. 
     
     
       15. A portable electronic device as recited in  claim 1 , wherein said speaker is a piezoelectric speaker. 
     
     
       16. A portable electronic device as recited in  claim 1 , wherein said portable electronic device is a handheld electronic device. 
     
     
       17. A portable electronic device, comprising
 a housing; 
 electrical components provided within said housing; 
 an internal structure provided within said housing; 
 a speaker provided within said housing and attached to said internal structure; and 
 a form-in-place seal provided within said housing, said form-in-place seal being used to at least in part form an acoustic chamber for said speaker, 
 wherein said internal structure comprises a EMI shielding structure, and wherein said EMI shielding structure includes one or more first openings in a top surface, and includes one or more second openings in at least one side surface, and 
 wherein at least one of the one or more second openings is substantially sealed with said form-in-place seal. 
 
     
     
       18. A portable electronic device as recited in  claim 17 , wherein the acoustic chamber includes a substantially isolated volume of air. 
     
     
       19. A portable electronic device as recited in  claim 17 , wherein one or more of said electrical components are provided within the acoustic chamber. 
     
     
       20. A portable electronic device as recited in  claim 17 , wherein said speaker is configured within said housing of said portable electronic device to have a front volume and a back volume, with the back volume being isolated from the front volume. 
     
     
       21. A portable electronic device as recited in  claim 20 , wherein an interface between the front volume and the back volume is provided in part by said EMI shielding structure. 
     
     
       22. A portable electronic device as recited in  claim 20 , wherein said form-in-place seal is arranged to isolate at least a part of the back volume from the front volume. 
     
     
       23. A portable electronic device as recited in  claim 17 , wherein said speaker is attached on the top surface of said EMI shielding structure such that the one or more first openings are covered by said speaker. 
     
     
       24. A portable electronic device as recited in  claim 17 , wherein said portable electronic device further comprises at least one gasket to assist with forming the acoustic chamber for said speaker. 
     
     
       25. A portable electronic device as recited in  claim 24 , wherein said speaker is configured within said portable electronic device to have a front volume and a back volume, with the back volume being isolated from the front volume. 
     
     
       26. A portable electronic device as recited in  claim 25 , wherein an interface between the front volume and the back volume is provided by said EMI shielding structure, said at least one gasket and said form-in-place seal. 
     
     
       27. A portable electronic device as recited in  claim 26 , wherein said speaker is a piezoelectric speaker. 
     
     
       28. A portable electronic device as recited in  claim 17 , wherein said portable electronic device is a handheld electronic device. 
     
     
       29. A portable electronic device as recited in  claim 17 , wherein said form-in-place seal has a low viscosity when placed within said housing and is thereafter cured to a higher viscosity. 
     
     
       30. A portable electronic device as recited in  claim 17 , wherein said speaker is a flat speaker.

Description:
CROSS-REFERENCE TO OTHER APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 61/094,816, filed Sep. 5, 2008, entitled “COMPACT HOUSING FOR PORTABLE ELECTRONIC DEVICE WITH INTERNAL SPEAKER”, which is hereby incorporated herein by reference. 
     This application also references U.S. Provisional Patent Application No. 61/094,811, filed Sep. 5, 2008, entitled “ELECTROMAGNETIC INTERFERENCE SHIELDS WITH PIEZOS”, which is hereby incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     Conventionally, a dedicated area within an electronic device housing is used to provide a chamber for a speaker. The speaker is utilized by the electronic device to produce audio sound for the benefit of the user of the electronic device. For example, the speaker can produce audio sounds corresponding to music, movies or speech. Unfortunately, however, as electronic devices become increasingly more compact, the availability of space within a housing for a compact electronic device becomes more limited. Accordingly, given the constrained geometries and tight tolerances of compact portable electronic devices, such as handheld portable electronic devices, it is increasingly difficult to provide a speaker with a desired acoustic chamber. 
     Piezoelectric speakers are often used in compact portable electronic devices, such as portable media players and mobile telephones, because of their low profile and relatively small footprint. Piezoelectric speakers create sound by forming vibrations with a diaphragm via a piezoelectric driver. In general, the sound quality associated with piezoelectric speakers is adequate, but is often not to the level that may be desired in particular applications. The sound quality associated with piezoelectric speakers may be worsened by the actual placement of the piezoelectric speakers within electronic devices. That is, the location at which a piezoelectric speaker is placed may not be a location which is not substantially optimal for the performance of the piezoelectric speaker. Piezoelectric speakers are often placed wherever they fit within electronic devices, without regard for whether the placement of the piezoelectric speakers provides substantially the best sound quality that may be achieved by the piezoelectric speakers. 
     Thus, there is a need for improved techniques for forming an acoustic chamber for a speaker, such as a piezoelectric speaker, within an electronic device housing. 
     SUMMARY OF THE INVENTION 
     The invention pertains to improved approaches for providing a speaker within a housing of a portable electronic device. The housing of the portable electronic device can be compact, such as a low profile housing. The portable electronic device can pertain to a portable digital media player, a mobile telephone, personal digital assistant, etc. 
     According to one aspect of certain embodiments of the invention, an acoustic chamber (e.g., back volume) for a speaker can be formed internal to a housing for a portable electronic device using non-dedicated space. According to another aspect of certain embodiments of the invention, irregular surfaces can be sealed so that an acoustic chamber for a speaker can be formed internal to a housing for a portable electronic device. Advantageously, an acoustic chamber for a speaker can be expanded and flexibly formed even within a low profile housing. In one embodiment, the speaker can be a piezoelectric loudspeaker. 
     The invention may be implemented in numerous ways, including, but not limited to, as a system, device, apparatus, or method. Example embodiments of the present invention are discussed below. 
     As a portable electronic device, one embodiment of the invention can, for example, include at least: a housing; a speaker provided in the housing; a back volume for the speaker; and a front volume for the speaker. The back volume is formed from an area within the housing that is not dedicated to the back volume, and the front volume is formed from an area within the housing that is not dedicated to the front volume. 
     As a portable electronic device, another embodiment of the invention can, for example, include at least: a printed circuit board; electrical components mounted on the printed circuit board; a EMI shielding structure attached to the printed circuit board and provided over one of more of the electrical components; a speaker attached to the EMI shielding structure; and a form-in-place seal used to at least in part form an acoustic chamber for the speaker. 
     As a method for assembling a portable electronic device having an internal acoustic back volume, one embodiment of the invention can, for example, include at least: obtaining a printed circuit board; attaching electrical components to the printed circuit board; attaching an EMI shielding can to the printed circuit board such that the EMI shielding can is placed over one or more of the attached electrical components; attaching a speaker to the EMI shielding can; applying a form-in-place sealant to one or more particular locations of the assembled printed circuit board; curing the form-in-place sealant; and thereafter assembling the portable electronic device such that the assembled printed circuit board is provided within a housing of the portable electronic device and such that the internal acoustic back volume is formed within the portable electronic device housing and coupled to the speaker. 
     As a portable electronic device, still another embodiment of the invention can, for example, include at least: a housing; electrical components provided within the housing; an internal structure provided within the housing; a speaker provided within the housing and attached to the internal structure; and a form-in-place seal provided within the housing, the form-in-place seal being used to at least in part form an acoustic chamber for the speaker. 
     Various aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a simplified sectional side view of a portable electronic device housing according to one embodiment of the invention. 
         FIG. 2  is a simplified sectional side view of a portable electronic device housing according to another embodiment of the invention. 
         FIG. 3  is a simplified sectional side view of a portable electronic device housing according to one embodiment of the invention. 
         FIG. 4A  is an upper perspective view of a board assembly according to one embodiment of the invention. 
         FIG. 4B  is an upper perspective view of a board assembly according to another embodiment of the invention. 
         FIG. 4C  is a simplified sectional side view of a portable electronic device housing according to one embodiment of the invention. 
         FIG. 5A  is an upper perspective view of a board assembly according to still another embodiment of the invention. 
         FIG. 5B  is an upper perspective view of a board assembly according to still another embodiment of the invention. 
         FIG. 6  is a flow diagram of an assembly process for a portable electronic device according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention pertains to improved approaches for providing a speaker within a housing of a portable electronic device. The housing of the portable electronic device can be compact, such as a low profile housing. The portable electronic device can pertain to a portable digital media player, a mobile telephone, personal digital assistant, etc. 
     According to one aspect of certain embodiments of the invention, an acoustic chamber (e.g., back volume) for a speaker can be formed internal to a housing for a portable electronic device using non-dedicated space. According to another aspect of certain embodiments of the invention, irregular surfaces can be sealed so that an acoustic chamber for a speaker can be formed internal to a housing for a portable electronic device. Advantageously, an acoustic chamber for a speaker can be expanded and flexibly formed even within a low profile housing. In one embodiment, the speaker can be a piezoelectric loudspeaker. 
     Embodiments of the invention are discussed below with reference to  FIGS. 1-6 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. 
       FIG. 1  is a simplified sectional side view of a portable electronic device housing  100  according to one embodiment of the invention. The portable electronic device housing  100  is a housing for a portable electronic device. The portable electronic device housing  100  can be of any material or combination of materials, such as metals, plastics, or ceramics. Typically, the portable electronic device (and thus the housing  100 ) is compact and highly portable, such as a handheld electronic device. 
     The portable electronic device housing  100  includes an internal structure  102  having a speaker  104  couples thereto. The internal structure  102  can represent any suitable structure within the portable electronic device housing  100 . For example, the internal structure  102  can pertain to a printed circuit board. As another example, the internal structure  102  can pertain to an Electrical Magnetic Interference (EMI) shielding can (also known as a RF can). In one embodiment, the speaker  104  can be a disc type speaker, such as a piezoelectric speaker. The speaker  104  can be secured with respect to the internal structure  102  by an adhesive seal  106 . The seal  106  can be provided around the periphery of the speaker  104  with respect to a front side of the speaker  104  that is secured to the internal structure  102 . In one embodiment, the adhesive seal  106  can be implemented by double-sided adhesive tape (e.g., VHB™ tape). 
     In addition, a first gasket  108  and a second gasket  110  can combine to form a back volume  112  adjacent a back side of the speaker  104 . The first gasket  108  and the second gasket  110  can create a seal above the back side of the speaker  104  and between the internal structure  102  and an inner surface of the housing  100 . The first gasket  108  and the second gasket  110  can rubber or other material that tends to be somewhat compliant. A front volume  114  for the speaker  104  can also be formed within the portable electronic device housing  100 . The back volume  112  and the front volume  114  are isolated (or nearly isolated) volumes of air that reside within an internal area of the portable electronic device housing  100 . 
     The portable electronic device housing  100  also includes an opening  116 . The opening  116  is adjacent the front volume  114  for the speaker  104 . The opening  116  can be a dedicated opening for the speaker  104  or can alternatively be an opening provided for another purpose. In this embodiment, the internal structure  102  will include at least one opening so that the front side of the speaker  104  can couple to the front volume  114 . Here, the sound waves produced by the speaker  104  can transmit through the front volume  114  and out of the opening  116  so that the resulting audio sound can be heard by a user (or bystander) associated with the portable electronic device. 
     As illustrated in  FIG. 1 , the back volume  112  is substantially sealed against the inner surface of the portable electronic device housing  100 . However, since the back volume  112  includes essentially the volume of air above the back surface of the speaker  104 , the back volume  112  is rather limited, particularly with portable electronic device housings that are compact, such as for handheld electronic devices. Since improved fidelity might be achieved by a larger back volume, different sealing configurations, arrangements or approaches can be used to obtain different back volumes. 
       FIG. 2  is a simplified sectional side view of a portable electronic device housing  200  according to another embodiment of the invention. The portable electronic device housing  200  is generally similar to the portable electronic device housing  100  illustrated in  FIG. 1 . However, the second gasket  110 ′ is positioned away from the speaker  104  so that the back volume  112 ′ is increased as compared to the back volume  112  in  FIG. 1 . While the first gasket  108  seals upward from the internal structure  102  to an upper, inner surface of the portable electronic device housing  200 , the second gasket  110 ′ seals downward from the internal structure  102  to a lower, inner surface of the portable electronic device housing  200 . 
       FIG. 3  is a simplified sectional side view of a portable electronic device housing  300  according to one embodiment of the invention. The portable electronic device housing  300  can represent a more detailed embodiment for the portable electronic device housing  200  illustrated in  FIG. 2 . 
     The portable electronic device housing  300  encloses a printed circuit board  302 . Various electrical components  304  are attached to the printed circuit board  302 . The electrical components  304  can pertain to integrated circuits, analog devices (e.g., resistor, capacitor, transistor), etc. that are often utilized by portable electronic devices. A battery  306  and a display  307 , which can be considered relatively large electrical components, can also be attached to the printed circuit board  302 . 
     In addition, the portable electronic device housing  300  can include an Electrical Magnetic Interference (EMI) shielding can  308 . The EMI shielding can  308  can also be referred to as an RF can. The EMI shielding can  308  can be mounted on the printed circuit board  302 . Typically, the EMI shielding can  308  covers or encloses one or more of the electrical components  304  so as to reduce EMI emissions. A speaker  310  can be coupled to an upper surface of the EMI shielding can  308 . In one embodiment, the speaker  310  can be a disc type speaker, such as a piezoelectric speaker. The speaker  310  can be secured with respect to the EMI shielding can  308  by an adhesive seal  312 . The adhesive seal  106  can be provided around the periphery of the speaker  310  with respect to a front side of the speaker  310  that is secured to the EMI shielding can  308 . In one embodiment, the adhesive seal  106  can be double-sided adhesive tape. 
     In addition, a first seal  314  and a second seal  316  can combine to form a back volume  318  behind a back side of the speaker  310 . The first seal  314  and the second seal  316  can create a seal between the back volume  318  of the speaker  310  and a front volume  320  of the speaker  310 . The EMI shielding can  308  can include one or more openings  322  (e.g., holes) in its upper surface adjacent the speaker  310 . The opening  320  enables sound waves induced by the speaker  310  to propagate into the EMI shielding can  308 . The EMI shielding can  308  also include at least one opening  324  that allows the sound waves from the speaker  310  to exit the EMI shielding can  308 . The opening  324  is an opening of or into the front volume  320 . The portable electronic device housing  300  also includes an opening  326 . The opening  326  is coupled to the front volume  320  for the speaker  310  so that sound waves generated by the speaker  310  can exit the portable electronic device housing  300 . The opening  326  can be a dedicated opening for the speaker  310  or can alternatively be an opening provided for another purpose (e.g., connector opening). 
     Both the back volume  318  and the front volume  320  are formed internal to the portable electronic device housing  310 , though the internal components and seals are used to substantially isolate the front volume  320  from the back volume  318 . For example, as illustrated in  FIG. 3 , at a minimum to isolate the front volume  320  from the back volume  318 , the first seal  314  and the second seal  316  cooperate with portions of the EMI shielding can  308  and the printed circuit board  302 . 
       FIG. 4A  is an upper perspective view of a board assembly  400  according to one embodiment of the invention. The board assembly  400  has a printed circuit board  402  as a base. Electrical components  404  are attached to the printed circuit board  202  and are electrically interconnected via metal traces provided on the printed circuit board. The electrical components  404  can pertain to integrated circuits, analog devices (e.g., resistor, capacitor, transistor), etc. that are often utilized by portable electronic devices. A battery  406  can also be attached or placed proximate to the printed circuit board  402 . Still further, an Electro-Magnetic Interference (EMI) can  408  can be attached to the printed circuit board  402 . A speaker  410  can be coupled proximate to a top surface of the EMI can  408 . An intermediate layer (not shown) can be provided between the top surface of the EMI can  408  and the speaker  410 . For example, the intermediate layer can pertain to a layer of adhesive provided around the periphery of the speaker  410  so as to secure and seal the front side of the speaker  410  to the top surface of the EMI can  408 . In one embodiment, the intermediate layer can be double-sided adhesive tape. 
     The EMI can  410  can include one or more openings in a top surface (not shown, see  FIG. 3 ) that enable sound waves produced by the speaker  410  to enter the EMI can  408 . The EMI can  408  is also substantially sealed with respect to the printed circuit board  402  with the exception of an opening  412  in one side of the EMI can  408 . 
       FIG. 4B  is an upper perspective view of a board assembly  400  according to another embodiment of the invention. The board assembly  440  is generally similar to the board assembly  400  illustrated in  FIG. 4A . However, the board assembly  440  further includes a barrier  442 . When the board assembly  440  is provided with a portable electronic device housing, the barrier  442  operates to seal with respect to one or more inner sides of the portable electronic device housing. Consequently, the barrier  442  provides a demarcation between a front volume and a back volume for the speaker  410 . Interestingly, the barrier  442  can be provided over irregular surfaces, yet still provide a reliable seal. For example, as shown in  FIG. 4B , the barrier  442  has it lower surface sealed against a portion of the printed circuit board  402 , the EMI shielding can  408  and the electrical components  404 . The formation of the barrier  442  is such that the lower surface of the barrier  442  is able to be formed over the different heights. In one embodiment, as discussed in greater detail below, the barrier  442  can be formed from a liquid or gel that can easily conform to irregular surfaces, and can then cure to a sold form. The resulting barrier  442  not only seals against the irregular surfaces but also typically remains compliant so that it can be compressed against when forming a seal. In one implementation, the barrier  442  can be formed from a form-in-place material. 
       FIG. 4C  is a simplified sectional side view of a portable electronic device housing  460  according to one embodiment of the invention. The portable electronic device housing  460  represents a housing for a portable electronic device that encloses the board assembly  440  illustrated in  FIG. 4B . The sectional side view of the portable electronic device housing  460  illustrates a sectional view along reference line A-A′ illustrated in  FIG. 4B . 
     The portable electronic device housing  460  represents a housing for a portable electronic device that contains the board assembly  440 . As illustrated in  FIG. 4C , the barrier  442  provided on an upper surface of the printed circuit board  402  can be used as a seal between the inner, upper surface  461  of the portable electronic device housing  462  and the EMI shield can  408 . More generally, the barrier  442  also seals downward against the surface of the printed circuit board  402 , one or more electronic devices  404  attached to the printed circuit board  402 , and/or the EMI shielding can  408 . As shown, the EMI sealing can  408  encloses the electronic devices  404 ′. Other cross sectional views of the portable electronic device housing  460  can illustrate the barrier  442  sealing downward against the surface of (i) the printed circuit board  402 , and/or (ii) the one or more electronic devices  404  attached to the printed circuit board  402 . 
     In addition, a first seal  462  and a second seal  464  can combine to form a back volume  466  behind a back side of the speaker  410 . The first seal  462  and the second seal  464  can create a seal between the back volume  466  of the speaker  410  and a front volume  468  of the speaker  410 . The EMI shielding can  408  can include one or more openings (e.g., holes) in its upper surface adjacent the speaker  410 . The openings enable sound waves induced by the speaker  410  to propagate into the EMI shielding can  408 . The EMI shielding can  408  also includes at least one opening  470  that allows the sound waves from the speaker  410  to exit the EMI shielding can  408 . The opening  470  is an opening of or into the front volume  468 . The portable electronic device housing  460  also includes an opening  472 . The opening  472  is coupled to the front volume  468  for the speaker  410  so that sound waves generated by the speaker  410  can exit the portable electronic device housing  460 . The opening  472  can be a dedicated opening for the speaker  410  or can alternatively be an opening provided for another purpose (e.g., connector opening). 
       FIG. 5A  is an upper perspective view of a board assembly  500  according to still another embodiment of the invention. The board assembly  500  is generally similar to the board assembly  440  illustrated in  FIG. 4B . However, the board assembly  500  further details that the EMI shielding can  408  can include other openings  502  besides the opening  412 . With the barrier  442 , the opening in the EMI shielding can  408  provide a path for sound waves from the speaker  410  to pass out of the EMI shielding can  408  to a remaining portion of a front volume. However, this implies that the volume within the EMI shielding can  408  is part of the front volume and thus needs to be isolated from the back volume. Accordingly, to the extent that the EMI shield can  408  includes additional openings  502  beyond the opening  412 , the additional openings  502  need to be covered, filled or otherwise sealed to isolate the front volume inside the EMI shielding can  408  from the back volume outside the EMI shielding can  408 . 
       FIG. 5B  is an upper perspective view of a board assembly  500 ′ according to still another embodiment of the invention. The board assembly  500 ′ represents the board assembly  500  illustrated in  FIG. 5A  with the additional openings  502  filled by a form-in-place material  520 . In one implementation, the form-in-place material can be applied in a liquid for so as to easily conform to irregular surfaces and then cure to form a solid seal. The resulting solid seal is typically compliant so as to facilitate sealing with pressure on the seal. The form-in-place material  520  can pertain to liquid silicone, unset epoxy, or foam. 
     In alternative embodiment, the openings  502  can be sealed by other materials. For example, the opening  502  can be cover, such as with an adhesive tape, or filled with a substance, such as silicone, metal or rubber. 
       FIG. 6  is a flow diagram of an assembly process  600  for a portable electronic device according to one embodiment of the invention. The assembly process  600  serves to assemble a housing for a portable electronic device. 
     The assembly process  600  can initially obtain  602  a printed circuit board. Electrical components can then be attached  604  to the printed circuit board. In addition, an Electro-Magnetic Interference (EMI) shielding can is then attached  606  to the printed circuit board. In doing so, the EMI shielding can typically covers one or more of the electrical components attached to the printed circuit board. Next, a speaker can be attached  608  to the EMI shielding can. 
     A form-in-place sealant can then be applied  612  to particular locations. For example, the form-in-place sealant can be applied to seal internal regions of the housing for the portable electronic device such that a back volume and a front volume for the speaker are distinctly formed. The form-in-place sealant can be applied over irregular surfaces, thereby allowing the demarcation between the back volume and the front volume to be flexibly established regardless of internal structure. For example, the form-in-place sealant can be provided over a plurality of electrical components formed on a printed circuit board (see, e.g.,  FIG. 5A ). As another example, the form-in-place sealant can be provided to seal openings with respect to the EMI shielding can (see, e.g.,  FIG. 5B ). In one implementation, the form-in-place sealant is applied as a liquid so that it is able to conform to irregular geometries. As an example, the form-in-place sealant can be extruded into place. 
     After the form-in-place sealant has been applied  610 , the form-in-place sealant is cured  612 . In one implementation, the form-in-place sealant is cured  612  through use of heat. In another implementation, the form-in-place sealant is cured  612  through use of ultraviolet radiation. In still another implementation, the form-in-place sealant can be cured  612  in an ambient environment. 
     Thereafter, the end product can be assembled  614 . The end product, namely, a portable electronic device, has a housing that contains the assembled printed circuit board. In doing so, one more gaskets may be utilized to seal portions of the assembled printed circuit board to interior surfaces of the housing so that a back volume and a front volume can be distinctly formed within the interior of the housing for the portable electronic device. While gaskets can be utilized to certain seal certain areas, in other regions form-in-place material can be used to seal or assist in sealing. For example, to the extent that sealing is to be provided over an irregular surface, conventional rubber gaskets are not able to provide an adequate seal; hence, the form-in-place material can be applied to seal such regions, alone or combination with one or more gaskets. 
     Although the assembly process  600  discussed above is for processing a printed circuit board for a single housing at a time, it should be understood that the assembly process could also concurrently process an array or sheet of printed circuit boards. For example, the operations  602 - 612  can be perform on an array or sheet of printed circuit boards to produce assembled printed circuit boards, and then final assembly of the individual printed circuit boards can be performed at operation  614 . 
     A portable electronic device as discussed herein may be a hand-held electronic device. The term hand-held generally means that the electronic device has a form factor that is small enough to be comfortably held in one hand. A hand-held electronic device may be directed at one-handed operation or two-handed operation. In one-handed operation, a single hand is used to both support the device as well as to perform operations with the user interface during use. In two-handed operation, one hand is used to support the device while the other hand performs operations with a user interface during use or alternatively both hands support the device as well as perform operations during use. In some cases, the hand-held electronic device is sized for placement into a pocket of the user. By being pocket-sized, the user does not have to directly carry the device and therefore the device can be taken almost anywhere the user travels. 
     Additional information on use of piezoelectric speakers and EMI shielding cans within electronic device housings can be found in U.S. patent application Ser. No. 61/094,811, filed concurrently, entitled “Electromagnetic Interference Shields with Piezos”, which is herein incorporated herein by reference. 
     Also, as discussed above, a portable electronic device housing can include an opening (or aperture) so that sound waves generated by a speaker can exit the portable electronic device housing. When the opening is provided for another purpose (e.g., connector opening), it can be referred to as a dual-purpose aperture. Additional information on dual-purpose apertures can be found in U.S. patent application Ser. No. 12/016,584, filed Jan. 18, 2008, and entitled “DUAL-PURPOSE HARDWARE APERTURE”. 
     The advantages of the invention are numerous. Different embodiments or implementations may, but need not, yield one or more of the following advantages. One advantage of certain embodiments of the invention is that speakers can be used with compact housings for portable electronic devices while using minimal space within the housings. Another advantage of certain embodiments of the invention is that improved acoustic chambers can be provided within portable electronic device housings using non-dedicated areas and improved sealing techniques. For example, according to one embodiment, an acoustic chamber can yield high quality sound without needing a dedicated area within a housing of a portable electronic device. 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Metadata:
Filing Date: 20080929
Publication Date: 20120911
Grant Date: 20120911
Priority Date: 20080905
Inventors: LIN GLORIA
BARRENTINE DEREK B.
ROSENBLATT MICHAEL
Assignee: APPLE INC
CPC Classifications: [{"code": "H04R1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49005", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K9/0037", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K9/0037", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49005", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R17/00", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 41799322