PATENT DOCUMENT

Publication Number: US-8472203-B2
Application Number: US-20435008-A
Country: US
Kind Code: B2

Title: Assembly of a handheld electronic device

Abstract:
This invention is directed to several mechanical features of an electronic device. The electronic device may include a spring for simultaneously grounding several components. The electronic device may include several interlocking fences for protecting electronic device components from RF radiation. The electronic device may include an antenna assembly that includes distinct components for functional and aesthetic purposes. The electronic device may include a window for permitting RF transmissions. The electronic device may include a metal frame for stiffening the electronic device. The electronic device may include a bezel used for aesthetic purposes and to support numerous electronic device components. The electronic device may include a flexible housing operative to elastically deform to assemble the electronic device. The electronic device may include an unsupported button.

Claims:
What is claimed is: 
     
       1. An antenna assembly arranged within an electronic device operative to perform wireless communications operations, the antenna assembly comprising:
 an antenna for performing wireless communications operations; and 
 a radio-transparent antenna chassis operative to receive the antenna, the radio-transparent antenna chassis coupled to an inside surface of a radio-opaque housing of the electronic device, the radio-opaque housing having an aperture carved from a curved surface of the radio opaque housing; and 
 a radio-transparent antenna cap operative to close the aperture, the antenna cap inserted into the aperture from the outside of the radio-opaque housing by deforming the antenna cap, wherein the inserted antenna cap provides a smooth exterior surface across the aperture of the housing that fits tightly within the aperture to provide a flush outer surface for the electronic device, and wherein the inserted radio-transparent antenna cap is directly adjacent to the radio transparent antenna chassis. 
 
     
     
       2. The antenna assembly of  claim 1 , further comprising:
 a metallic grounding spring in direct contact with both the antenna and the radio-transparent housing, 
 wherein the metallic grounding spring comprises a tab configured to fit into a slot of the antenna such that the metallic grounding spring is retained in position. 
 
     
     
       3. The antenna assembly of  claim 2 , wherein each cut forming the aperture is perpendicular to the outer surface of the housing at the location of the cut. 
     
     
       4. The antenna assembly of  claim 1 , wherein the radio-transparent antenna chassis is manufactured from one of low density plastic and foam. 
     
     
       5. The antenna assembly of  claim 2 , wherein the radio-transparent antenna chassis is manufactured from foam and the antenna is woven into the antenna chassis. 
     
     
       6. The antenna assembly of  claim 1 , wherein the radio-transparent antenna cap includes a plurality of tabs operative to engage a portion of the inner surface of the housing when the radio-transparent antenna cap is inserted in the aperture. 
     
     
       7. The antenna assembly of  claim 1 , wherein the radio transparent antenna cap is manufactured using a forced ejection molding process. 
     
     
       8. The antenna assembly electronic device of  claim 1 , further comprising:
 a screen; and 
 a bezel, the bezel operative to be coupled with the housing and operative to receive the screen, the bezel comprising a window through which at least some radiation emanating from the antenna passes. 
 
     
     
       9. The antenna assembly of  claim 8 , wherein the aperture is aligned with the antenna chassis. 
     
     
       10. The antenna assembly of  claim 8 , wherein a portion of the screen that is over the aperture is opaque.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 60/967,565, filed Sep. 4, 2007, which is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention is directed to mechanical features of an electronic device. 
     SUMMARY OF THE INVENTION 
     An electronic device is provided. In some embodiments, the electronic device may include a spring for grounding a bezel, a housing, and an antenna board of the electronic device. The spring may include a base that has several of apertures, each aperture operative to receive a post extending from the top surface of a wall of the bezel. The spring may also include an inner tab extending from the base that follows the inner surface of the bezel wall and is operative to contact the antenna board mounted in the bezel. The spring may also include an outer tab extending from the base following the outer surface of the bezel wall and operative to contact the housing when the bezel is engaged with the housing. 
     In some embodiments, the bezel and housing of the electronic device may be electrically coupled and serve as a ground for the electronic device components. Electronic device components mounted in the housing may be electrically coupled to a circuit board of the bezel using a spring, and coupled to the housing to ground the component, for example using a flex (e.g., instead of being grounded to the board using a second connection). 
     The electronic device may include a circuit board protected from RF radiation. The circuit board may include a first board and a second board, the first board coupled to the second board by at least one flex tab. The circuit board may further include a first fence placed around the periphery of the components of the first board, and including at least one tab with a snap extending beyond the fence. The circuit board may still further include a second fence placed around the periphery of the components of the second board, and including at least one slot in the second fence. The first board may be operative to be placed over the second board by folding the circuit board with the at least one flex such that the first fence may be coupled to the second fence by engaging the tab and snap of the first fence with the slot of the second fence. 
     The electronic device may include one or more circuit boards. A circuit board may include a first board, a second board, a first flex tab electrically coupling the first board and the second board, and a second flex tab coupling the first board and the second board. The first board may be folded over the second board by bending the flex tabs. 
     The electronic device may include one or more antennas for performing wireless communications. In some embodiments, the electronic device may include an antenna chassis for receiving an antenna placed adjacent to an aperture in the housing. The electronic device may also include an antenna cap for closing the aperture, where the antenna cap may be inserted in the aperture from the outside of the housing by deforming the antenna cap. In some embodiments, the bezel may include a window for allowing radiation to pass through the front surface of the electronic device to enhance wireless communications. A screen or display inserted in the bezel may be rendered partially opaque to hide the window from view. 
     In some embodiments, the electronic device may include a plate operative to be coupled to the bezel behind the screen to support the screen. The plate may be rigid such that, when coupled to the bezel (e.g., using screws), the combination of the plate and bezel is stiff and resists to both torsion and bending stresses. 
     In some embodiments, the bezel may be used both as an aesthetically pleasing or as a cosmetic component, and as a functional component for supporting the components of the electronic device. In some embodiments, all or substantially all of the electronic device components may be mounted to the bezel. 
     The electronic device may be assembled using any suitable approach. In some embodiments, the bezel may include a slot operative to receive a latch welded into the housing. When the bezel is inserted in the housing, the housing may elastically deform to let the bezel pass, then return to its initial position once the latches engage the bezel slots. 
     In some embodiments, the electronic device may include a button (e.g., a home button). Because of the limited space inside the electronic device, the button may not be mounted on a distinct component, but may instead be captured by the bezel and the screen. The button may include several flanges extending from the button that may be received by slots in the bezel. Once in the button is in the bezel, the screen may be placed in the bezel such that only the center of the button (i.e., not the flanges) is accessible through the screen and the flanges are trapped between the bezel and the screen. The button may be directly coupled to a dome switch mounted on a circuit board located underneath the switch. 
    
    
     
       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 schematic view of a grounding spring placed between a bezel and an antenna board of an electronic device in accordance with one embodiment of the invention; 
         FIG. 1B  is a schematic view of a grounding spring placed between a bezel and an antenna board of an electronic device in accordance with one embodiment of the invention; 
         FIG. 1C  is a schematic view of the grounding spring of  FIG. 1B  in accordance with one embodiment of the invention; 
         FIG. 2A  is a perspective view of an electronic device having a spring for grounding several components of the electronic device in accordance with one embodiment of the invention; 
         FIG. 2B  is a schematic view of a spring for simultaneously grounding an antenna board, a bezel and a housing of an electronic device in accordance with on embodiment of this invention; 
         FIG. 3A  is a schematic view of an illustrative electronic device having a button in accordance with one embodiment of the invention; 
         FIG. 3B  is a schematic view of a block diagram depicting the electrical connections shown in  FIG. 3A  in accordance with one embodiment of the invention; 
         FIG. 4  is a schematic view of a circuit board with fences used to protect circuit board components in accordance with one embodiment of the invention 
         FIG. 5  is a schematic view of fences of the first and second boards of  FIG. 4  when they are approached to be engaged in accordance with one embodiment of the invention; 
         FIG. 6  is a schematic view of the fences of the first and second boards of  FIG. 5  when they are engaged in accordance with one embodiment of the invention; 
         FIG. 7  is a cross-sectional view of the board of  FIG. 4  when the board is folded in accordance with one embodiment of the invention; 
         FIG. 8  is a schematic view of the board of  FIG. 4  when the board is folded in accordance with one embodiment of the invention; 
         FIG. 9  is a schematic view of an electronic device housing in accordance with one embodiment of the invention; 
         FIG. 10  is an exploded view of an electronic device having an antenna assembly operative to transmit RF waves through the front of the electronic device in accordance with one embodiment of the invention; 
         FIG. 11  is a schematic view of the electronic device of  FIG. 10  when it is partially assembled; 
         FIG. 12  is a top view of the assembled electronic device of  FIG. 10  in accordance with one embodiment of the invention; 
         FIG. 13  is a schematic view of a bezel in accordance with one embodiment of the invention; 
         FIG. 14  is an exploded view of the bezel of  FIG. 13  with additional components in accordance with one embodiment of the invention; 
         FIG. 15  is a schematic view of the electronic device of  FIG. 14  when the electronic device is assembled in accordance with one embodiment of the invention; 
         FIGS. 16 ,  17  and  18  are schematic views of a bezel of an electronic device in accordance with one embodiment of the invention; 
         FIG. 19  is a cross-sectional view of an electronic device as a bezel is brought into contact with a housing in accordance with one embodiment of the invention; 
         FIG. 20  shows a cross-sectional view of the electronic device of  FIG. 19  once the bezel engages the housing in accordance with one embodiment of the invention; and 
         FIG. 21  is an exploded view of an electronic device that includes a home button in accordance with one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1A  is a schematic view of an illustrative electronic device in accordance with one embodiment of the invention. Electronic 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 a case formed from a bezel and a housing, a screen for displaying information to a user, and a user interface (e.g., a button) for providing inputs to the device. 
       FIG. 1B  is a schematic view of a grounding spring placed between a bezel and an antenna board of an electronic device in accordance with one embodiment of the invention.  FIG. 1C  is a schematic view of the grounding spring of  FIG. 1B  in accordance with one embodiment of the invention. Electronic device  100  may include bezel  130 , which may act as a ground for the electronic device components of the electronic device. The electronic device may include an antenna for performing wireless communications (e.g., using RF waves, as described in more detail below). To improve the performance of the antenna, it may be desirable to ground antenna board  120 , which may be part of the antenna assembly, to bezel  130 . Antenna board  120  may be ground to bezel  130  using any suitable approach. In some embodiments, a grounding spring may be placed between antenna board  120  and bezel  130 . For example, a spring constructed from electrically conductive material (e.g., a metal) may be inserted between antenna board  120  and bezel  130 . 
     Grounding spring  110  may be any suitable spring for grounding antenna board  120 . Grounding spring  110  may include elongated strip  112 , which may be operative to deform elastically when it is placed between antenna board  120  and bezel  130 . At each tip of strip  112 , spring  110  may include plate  114  that includes one or more tabs  116 . Each plate  114  may be operative to fit into a structure of antenna board  120  when spring  110  is placed between antenna board  120  and bezel  130  such that tabs  116  extend into slots  122  of antenna board  120 , thus retaining spring  110  in its position. 
     Spring  110  may be operative to deform elastically to accommodate for bumps  124  and grooves  125  in each of antenna housing  120  and bezel  130 . For example, antenna housing  120  and bezel  130  may include interlocking, wavy, or rippled surfaces to which spring  110  may conform. The redundant contacts due to the wavy nature of the interface, and of the spring in contact with the interface may provide a redundant and more consistent grounding mechanism. The elastic deformation of spring  110  may cause spring  110  to remain retained between antenna board  120  and bezel  130 , even during drop events or other impacts, such that antenna board  120  always remains grounded to bezel  130 . 
       FIG. 2A  is a perspective view of an electronic device having a spring for grounding several components of the electronic device in accordance with one embodiment of the invention. Electronic device  200  may include housing  210  and bezel  230 , which may be coupled to form the outer shell of electronic device  200 . Housing  210  may include plate  212  and side walls  214 . Plate  212  may form the back surface of electronic device  200 . In some embodiments, plate  212  may define a substantially flat surface (e.g., a flat surface or a surface with a small curvature defined, for example, by a spline). Side walls  214  may extend from plate  212  to form at least a portion of the walls of electronic device  200 . Walls  214  may include a curved surface by which the curvature of housing  210  changes from substantially parallel to plate  212  (e.g., horizontal) to substantially perpendicular to plate  212  (e.g., substantially vertical). In some embodiments, walls  214  may be short (e.g., in the range of 1 to 4 mm) such that only a small amount of the total height of walls  214  consists of material substantially perpendicular to plate  212  (e.g., vertical material). 
     Housing  210  may be manufactured from any suitable material and using any suitable process. For example, housing  210  may be manufactured from a metal (e.g., aluminum or stainless steel), a composite material, plastic, or any other suitable material. Housing  210  may be manufactured using any suitable approach, including for example forming, forging, extruding, machining, molding, stamping, combinations thereof, or any other suitable manufacturing process. 
     Housing  210  may include any suitable feature for coupling housing  210  to bezel  230  or for receiving other electronic device components. For example, housing  210  may include aperture  216  for receiving an antenna assembly. As another example, the inner surface of walls  214  may include slots or a component having slots operative to receive snaps of bezel  230  used to couple bezel  230  to housing  210 . As still another example, housing  210  may include features for supporting a circuit board or battery of the electronic device. 
     Bezel  230  may include curved outer surface  232  operative to form a flush coupling with walls  214  of housing  210 . Bezel  230  may include a number features on inner surface  234  for receiving electronic device components or for coupling bezel  230  to housing  210 . In some embodiments, bezel  230  may include one or more walls  236  having snaps operative to engage housing  210  when electronic device  200  is assembled, as discussed in more detail below. Walls  236  may be located around the periphery of bezel  230  as a continuous wall or as several discreet walls (e.g., one discreet wall along each side of the bezel). In some embodiments, a portion of walls  236  may include one or more posts  238  operative to receive grounding spring  250 . In some embodiments, bezel  230  may include aperture  240  operative to receive antenna board  260 . 
     Bezel  230  may be manufactured from any suitable material and using any suitable process. For example, bezel  230  may be manufactured from a metal (e.g., aluminum or stainless steel), a composite material, plastic, or any other suitable material. Bezel  230  may be manufactured using any suitable approach, including for example forming, forging, extruding, machining, molding, stamping, combinations thereof, or any other suitable manufacturing process. 
     Electronic device  200  may include antenna board  260  operative to support an antenna for wireless communications. For example, antenna board  260  may include an antenna and associated circuitry for conducting communications over an RF communications link, a microwave communications link, an IR communications link, or any other communications link (e.g., using any suitable frequency in the electro-magnetic spectrum). 
     To improve the antenna performance (e.g., RF performance and RF consistency), antenna board  260  may be grounded simultaneously to bezel  230  and to housing  210  using grounding spring  250 .  FIG. 2B  is a schematic view of a spring for simultaneously grounding an antenna board, a bezel and a housing of an electronic device in accordance with on embodiment of this invention. Spring  250  may include base  251  operative to rest on wall  236  of bezel  230 . In some embodiments, base  251  may operative to rest on a portion of wall  236  that curves (e.g., at a corner of bezel  230 ), and thus base  251  may be curved to follow the curvature of wall  236 . Base  251  may include several apertures  252  operative to receive posts  238  of bezel  230 . By placing posts  238  in apertures  252 , spring  250  may be easily and consistently mounted to a proper position on walls  236 . Once mounted on walls  236 , spring  250  may ground bezel  230 . In some embodiments, spring  250  may include a double armed flexure (e.g., U-shaped) connected to bezel  230  at a discrete point. 
     Spring  250  may include several inner tabs  253  extending from base  251  (e.g., six inner tabs  253 ). Inner tabs  253  may extend out of the plane of base  251  to follow the curvature and inner side of walls  236 . The length of inner tabs  253  may be selected to reach antenna board  260  when electronic device  200  is assembled. In some embodiments, inner tabs  253  may be a small amount longer than necessary to reach antenna board  260  so that when the electronic device is assembled, tabs  253  are deformed slightly and press against antenna board  260 . This may allow tabs  253  to remain in contact and ground antenna board  260 , even when electronic device  200  is subject to drops or other impacts. The flexure in tabs  253  may allow spring  250  to provide tolerant interface between bezel  230  and antenna board  260 . 
     Spring  250  may include several outer tabs  254  (e.g., five outer tabs  254 ) extending from the opposite side of base  251  as inner tabs  253 . Outer tabs  254  may extend out of the plane of base  251  and follow the curvature and outer side of walls  236 . The thickness of outer tabs  254  and the distance between the outer surface of wall  236  and outer surface  232  of bezel  230  may be selected such that the inner surface of housing  210  is in contact with at least one outer tab  254  when housing  210  is coupled to bezel  230 . For example, outer tabs  254  may be constructed such that outer tabs  254  are maintained between bezel  230  and housing  210  in a press fit. 
     Spring  250  may be manufactured from any suitable material and using any suitable process. For example, spring  250  may be manufactured from a metal (e.g., copper, gold, or stainless steel), a composite material, flex, or any other suitable material that is electrically conductive. Spring  250  may be manufactured using any suitable approach, including for example forming, forging, machining, molding, stamping, combinations thereof, or any other suitable manufacturing process (e.g., stamping followed by forming). 
     In some embodiments, the housing may include a button that is electrically coupled to the circuit boards of the electronic device.  FIG. 3A  is a schematic view of an illustrative electronic device having a button in accordance with one embodiment of the invention.  FIG. 3B  is a schematic view of a block diagram depicting the electrical connections shown in  FIG. 3A  in accordance with one embodiment of the invention. Electronic device  300  may include housing  310  and button  320 . Button  320  may be coupled to the circuit boards of the electronic device (not shown) using flex circuit  322 . Flex circuit  322  may include bottom contact pad  323 , which may connect flex circuit  322  to housing  310  (e.g., using an electrically conductive adhesive). Flex circuit  322  may also include top contact pad  324 , which may be coupled to spring  330 , which may in turn be coupled to the main circuit boards of the electronic device (e.g., not shown). Spring  330  and top contact pad  324  may serve as an electrical connection between the circuit board and button  320 . Because housing  310  may be electrically conductive (e.g., metallic) and electrically coupled to the bezel (e.g., also metallic), connecting button  320  (e.g., flex circuit  322 ) to housing  310  using bottom contact pad  323  may suffice to ground button  320 . By using housing  310  to ground button  320 , a second connection between top flex pad  324  and the circuit board may not be necessary, which may save significant space in electronic device electronic device  300 . 
     Because the electronic device may include an antenna for wireless communications (e.g., over an RF communications link), other components of the electronic device, including for example circuit boards, may need to be shielded from RF waves.  FIG. 4  is a schematic view of a circuit board with fences used to protect circuit board components in accordance with one embodiment of the invention. Circuit board  400  may include rigid first board  402  and rigid second board  404  coupled by flex tabs  406  and  407 . Flex tabs  406  and  407  may be constructed from a supple material operative to bend to allow first board  402  to be placed over second board  404  to reduce the footprint of circuit board  400 . In some embodiments, at least one of flex tabs  406  and  407  may be electrically coupled to both first board  402  and second board  404  to ensure that the components of each board can communicate with each other. For example, flex tabs  406  and  407  may be part of a flex circuit integrated in circuit board  400 . 
     The components of each of boards  402  and  404  may be surrounded by fences  410  and  420 , respectively. Fences  410  and  420  may define periphery in which components are placed in boards  402  and  404 . Fences  410  and  420  may be coupled to boards  402  and  404 , respectively, using any suitable approach. For example, fences  410  and  420  may be coupled to boards  402  and  404  using an adhesive, tape, soldering, welding, a mechanical fastener (e.g., a screw), a press fit, or any other suitable approach. In some embodiments, fences  410  and  420  may not be electrically coupled to boards  402  and  404 . Fences  410  and  420  may include walls  412  and  422 , respectively, which may extend substantially perpendicularly from the surface of each of boards  402  and  404 , and have a height substantially equal to or larger than the height of the components (e.g., chips) of each of boards  402  and  404 . Walls  412  and  422  may extend substantially around the entire periphery of each of boards  410  and  420  to act as a shield against RF radiation emanating from the antenna that would reach the components of boards  402  and  404  from the side. Walls  412  and  414  may therefore be constructed from any suitable material operative to substantially prevent RF radiation from passing through (e.g., a metal). 
     To protect the components of boards  402  and  404  from RF radiation coming from above boards  402  and  404  (e.g., over walls  412  and  422 ), boards  402  and  404  may be folded over each other such that boards  402  and  404  form the top and bottom shields of the components of boards  402  and  404 . Any suitable approach may be used to hold boards  402  and  404  in their bent position. In some embodiments, fences  410  and  420  may be coupled using snaps, detents, catches, flexures, friction couplings, or any other suitable approach.  FIG. 5  is a schematic view of fences of the first and second boards of  FIG. 4  when they are approached to be engaged in accordance with one embodiment of the invention. Each of fences  410  and  420  may include several cross-bars  413  and  423 , respectively, for providing additional structure and rigidity to walls  412  and  422 . Cross-bars  413  and  423  be in any suitable shape, including for example straight bars, curved bars, or bars with shapes (e.g., S- or J-shapes). In some embodiments, some of cross-bars  413  and  423  may be spaced in fences  410  and  420  such that when fences  410  and  420  are engaged, cross-bars  413  and  423  are aligned. Cross-bars  413  and  423  may have any suitable width, including for example different widths in a particular fence  410  or  420 . In some embodiments, cross-bars  413  and  423  that are aligned may have substantially the same shape and width. 
     Any suitable approach may be used to engage fences  410  and  420 . For example, fences  410  and  420  may be coupled using an adhesive, hook and fastener material (e.g., Velcro®), a mechanical fastener (e.g., a screw), or mechanical components of fences  410  and  420 . In some embodiments, fence  410  may include several tabs  414  extending beyond portions of wall  412  such that tabs  414  fit around portions of wall  422  when fence  410  engages fence  420 . Fence  410  may include any suitable number of tabs  414  placed at any suitable intervals around the periphery of fence  410 . For example, fence  410  may include nine tabs  414 , four on each of the elongated sides of fence  410 , and one on a short side of fence  410 . Each tab  414  may include a snap  415  extending from tab  414  towards the inside of the perimeter defined by wall  412 . Snaps  415  may include an angled top surface  416  operative to allow walls  422  of fence  420  to slide past tabs  414  when fences  410  and  420  are engaged, and flat surface  417  operative to engage walls  422  to maintain fence  420  against fence  410 . 
     Snaps  415  may be operative to engage slots  424  of walls  422 . Slots  424  may be constructed in walls  422  such that, when fences  410  and  420  are engaged, snaps  415  are aligned with slots  422 . Walls  422  may include any suitable number of slots  422 , including for example as many slots  422  as snaps  415  in tabs  414 . Slots  424  may take any suitable form, including for example apertures in walls  424 , notches (e.g., that do not extend all the way through walls  424 ), protrusions extending from walls  424  operative to engage snaps  415 , or any other suitable form.  FIG. 6  is a schematic view of the fences of the first and second boards of  FIG. 5  when they are engaged in accordance with one embodiment of the invention. When fence  420  is placed over fence  410 , tabs  414  may be elastically bent outwards to allow walls  422  to pass before returning to its initial shape when snaps  415  engage slots  424 . If slots  424  are apertures, snaps  415  may be visible through walls  422  when fences  410  and  420  are engaged. 
       FIG. 7  is a cross-sectional view of the board of  FIG. 4  when the board is folded in accordance with one embodiment of the invention.  FIG. 8  is a schematic view of the board of  FIG. 4  when the board is folded in accordance with one embodiment of the invention. To prevent RF radiation from accessing board components by passing in between fences  410  and  420  when fences  410  and  420  are engaged, the positions of snaps  415  and slots  424  (e.g., the height of snaps  415  relative to the height of walls  412 , and the height of slots  424  relative board  404 ) may be selected such that fences  410  and  420  are substantially in contact or nearly in contact when engaged. In some embodiments, cross-bars  413  and  423  may be substantially in contact or nearly in contact to further engage fence  410  to fence  420 . For example, cross-bars  413  and  423  may be coupled (e.g., using an adhesive, a mechanical fastener, or components implemented on the cross-bars, such as snaps). As shown in  FIG. 7 , cross-bars  413  and  414  may be nearly in contact. 
     Once boards  402  and  404  are folded over each other and set in place by the engagement of fences  410  and  420 , the circuit board components of boards  402  and  404  may be protected from RF radiation from all directions. Walls  412  and  422  may prevent radiation from reaching the circuit board components from the side, and boards  402  and  404  may prevent radiation from reach the circuit board components from the bottom and top, respectively. Thus, the components of circuit board  400  may be protected from RF radiation without surrounding circuit board  400  with an additional entire box to protect the circuit board components from RF radiation, which may take up a significant amount of space in an electronic device that has only a limited amount of space available. In some embodiments, walls  412  and  422  may form a complete wall from a combination of portions (e.g., castleated alternating high and low portions) combining to form a continuous wall. In some embodiments, walls  412  and  422  may instead or in addition overlap to form a redundant wall when they come together. 
     Although only one flex tab  406  or  407  may be needed to provide an electrical coupling between boards  402  and  404 , circuit board  400  may include at least two flex tabs  406  and  407  connecting boards  402  and  404  to limit torsion stresses as first board  402  is folded over second board  404 . For example, circuit board  400  may include flex tab  406  at one end boards  402  and  404 , and flex tab  407  at an opposite end of boards  402  and  404 . Flex tabs  406  and  407  may have any suitable width, including different widths (e.g., a smaller width for the flex tab that is not used as a conductive path between boards  402  and  404 ). The widths of each of flex tabs  406  and  407  may be selected such that torsion stresses are minimized (e.g., due to the presence of both tabs opposing bending moments) using the least amount of material necessary (e.g., to reduce cost, weight, and space used in the electronic device). In some embodiments, board  400  may include more than two flex tabs, or one large flex tab spanning the entire or substantially the entire length of boards  402  and  404  to provide stiffness against torsion. 
       FIG. 9  is a schematic view of an electronic device housing in accordance with one embodiment of the invention. Housing  910  may include aperture  914  for receiving the antenna assembly. Aperture  914  may be carved out of a curved surface of housing  910 , including for example part of rear plate  911  and one or more walls  912  (e.g., from a corner of housing  910 ). Aperture  914  may be manufactured using any suitable approach. In some embodiments, aperture  914  may be manufactured as a feature of housing  910  when housing  910  is manufactured (e.g., aperture  914  is included in a stamp used to form housing  910 ). In some embodiments, aperture  914  may be cut into housing  910  once its shape been substantially defined. 
     Aperture  914  may be cut in housing  910  using any suitable approach. In some embodiments, aperture  914  may be created using punching, beam cutting (e.g., using a laser beam or a high pressure water beam), or any other suitable approach. By using beam cutting, aperture  914  may be precisely cut to enhance the fit of antenna cap  930  in aperture  914 . In some embodiments, aperture  914  may be cut such that the walls of aperture  914  are all perpendicular to the surface of housing  910 . When aperture  914  is cut from a curved portion of housing  910  (e.g., the corner of housing  910 ), one of the cutting beam or housing  910  may move to ensure that all cuts remain perpendicular to outer surface of housing  910 . For example, the cutting beam may be a laser cutter controlled on 2 axes, and housing  910  may be placed in a fixture operative to move along the last axis. Thus, the cutting beam may perform incisions in housing  910  as if it were a cutting beam controlled on 3 axes. 
     In some embodiments, the cutting beam may cut aperture  914  in a single, continuous cut. This may allow for a cleaner and more precise overall cut, and a faster manufacturing process. Once the cutting beam cuts aperture  914 , the edge of aperture  914  may be cleaned ultrasonically and/or tumbled to remove any extraneous material. This process may allow for a very tight reveal by which antenna cap  930  may mate tightly with aperture  914  to provide a flush outer surface for the electronic device. 
     Antenna assembly  920  may include antenna chassis  922  operative to receive an antenna, and antenna cap  930  operative to provide a radio-transparent cosmetic outer surface for antenna assembly  920 . Antenna chassis  922  may be mounted to the inner surface of housing  910  or of the bezel (e.g., bezel  230 ,  FIG. 2A ) using any suitable approach, including for example an adhesive, a mechanical fastener, a mechanical component built in housing  910  and/or antenna chassis  922  (e.g., a pin), or any other suitable approach. The shape of antenna chassis  922  may be specifically designed to maximize the antenna performance for wireless communications operations. Accordingly, it may be desirable to introduce a separate component to provide the cosmetic cover of chassis  922  to limit the constraints on chassis  922 . 
     Contrary to antenna chassis  922 , antenna cap  930  may be coupled to housing  910  from the outside of the housing. For example, antenna cap  930  may be manufactured such that the outer periphery  931  of cap  930  matches the periphery of aperture  914  and provides a press fit between cap  930  and aperture  914 . In some embodiments, cap  930  may include several tabs  932  extending from the edge of the inner surface of cap  930 . Tabs  932  may be operative to reach into the inner surface of housing  910  when cap  930  is mounted in aperture  914 . Cap  930  may include any suitable number of tabs, including for example one or two per side of cap  930  (e.g., 7 total tabs). 
     To mount cap  930  to housing  910 , cap  930  may be elastically deformed to fit into aperture  914  from the outside of housing  910  (e.g., instead of being placed in aperture  914  from the inside of housing  910 ). For example, the outer edges of cap  930  (e.g., around tabs  932 ) may be deformed as cap  930  is forced into aperture  914 . Once cap  930  is within the boundaries defined by aperture  914 , cap  930  may return to its initial shape and be flush with housing  910 . Tabs  932  may prevent cap  930  from moving out of aperture  914 , while the contact between curved periphery  931  of cap  930  and the edge of aperture  914  may prevent cap  930  from moving into housing  910 . The thickness and shape of cap  930  may be selected such that, once inserted in aperture  914 , cap  930  is flush with the outer surface of housing  910 . Once cap  930  is inserted in housing  910 , antenna chassis  922  may be mounted in the electronic device. 
     Antenna cap  930  may be manufactured using any suitable approach. In some embodiments, antenna chassis  922  and cap  930  may be manufactured from plastic, foam, or any other material that may allow radiation to pass through electronic device  900 . In some embodiments, cap  930  may be manufactured using a molding process that includes forced ejection of the cap. For example, because tabs  932  may extend beyond the periphery of cap  930 , cap  930  may be forcibly ejected in a manner that causes tabs  932  to deform elastically. In some embodiments, the manufacturing process may include several ejections. For example, first a moon gate runner may be ejected by an ejector pin to avoid the gate breaking in the sub-insert. Second, a stripper plate and ejector bar may be ejected to create space for the tabs to flex. Third, the ejector bar may be raised to eject the part from the undercut (e.g., while elastically deforming the tabs). 
     Antenna chassis  922  and antenna cap  930  may be formed from any material suitable for allowing electromagnetic waves (e.g., from the antenna) to pass. For example, antenna chassis  922  may be formed from a porous material that has low density, low dielectric, and low loss tangent, while still providing sufficient stiffness. It may be important to select such materials to enhance the antenna performance because the housing and bezel of the electronic device may be manufactured from metals, which may significantly reduce antenna performance. Suitable materials for antenna chassis  922  may include, for example, low density plastic such as polycarbonate (e.g., which may have a dielectric of 3) and foam (e.g., which may have a dielectric of 1.1). For example, a cast foam piece (e.g., two part epoxy expanding into mold) may provide a strong material that may be attached using means typically used for plastic components (e.g., using mechanical fasteners). To add an antenna to an antenna chassis  922  manufactured from foam, the antenna may be weaved into the chassis. In some embodiments, the antenna may be molded into an antenna chassis  922  manufactured from foam (e.g., place antenna inside foam chassis mold), which may protect the antenna from mechanical damage (e.g., during manufacturing of the electronic device) and from rusting (e.g., insert molding technique). 
     A foam antenna chassis may be manufactured using any suitable approach. For example, the foam chassis may be cast, machined, stamped, molded, combinations of these, or any other suitable approach. The cast foam may be sufficiently stiff to support mechanical components (e.g., pins or snaps), or receive mechanical fasteners (e.g., a screw). 
     In some embodiments, RF waves transmitted by the antenna may pass through the back of the electronic device, that is the housing (e.g., through cap  930 ), or through the front of the electronic device, that is the bezel and screen.  FIG. 10  is an exploded view of an electronic device having an antenna assembly operative to transmit RF waves through the front of the electronic device in accordance with one embodiment of the invention.  FIG. 11  is a schematic view of the electronic device of  FIG. 10  when it is partially assembled. Electronic device  1000  may include housing  1010 , bezel  1030  and window  1040 . Housing  1010  may include aperture  1014  for receiving antenna cap  1054 . Electronic device  1000  may include antenna chassis  1052  and antenna board  1053 , which may include an antenna for allowing the electronic device of electronic device  1000  to perform wireless communications operations. 
     Bezel  1030  may include beam  1032  extending across the width of bezel  1030 . In some embodiments, beam  1032  may extend substantially across the surface of antenna chassis  1052 . Because bezel  1030  may be metallic, and thus prevent RF radiation from the antenna from passing through its surface, beam  1032  may include aperture  1034  through which RF radiation may pass. Aperture  1034  may be any suitable size, including for example substantially the size of antenna chassis  1052 . In addition, aperture  1034  may be positioned in beam  1032  such that aperture  1034  is substantially aligned with the antenna. In some embodiments, antenna board  1053  may also include a window to allow an antenna mounted on antenna chassis  1052  to transmit RF radiation through the top surface of the electronic device. 
     Window  1040  may be placed over bezel  1030  and beam  1032  such that aperture  1034  is under window  1040 .  FIG. 12  is a top view of the assembled electronic device of  FIG. 10  in accordance with one embodiment of the invention. Window  1040  may be operative to protect the antenna from impacts or prevent undesired particles from passing through aperture  1034 . To hide aperture  1034  and antenna chassis  1052  from view (e.g., prevent aperture  1034  and antenna chassis  1052  from being visible through window  1040 , as shown in  FIG. 12 ), a portion of window  1040  may be coated with an opaque layer (e.g., a black layer). RF radiation may continue to pass through the opaque layer, but visible light may be blocked. 
     The outer periphery of the electronic device may be defined by a bezel coupled to a housing. The bezel may include an opening for receiving a window providing displays to a user.  FIG. 13  is a schematic view of a bezel in accordance with one embodiment of the invention. Bezel  1300  may include top end  1302 , bottom end  1304  and sides  1306 . Bezel  1300  may include large aperture  1310  defined by ends  1302  and  1304  and sides  1306  for receiving an electronic device screen. In some embodiments, bezel  1300  may include flange  1311  operative to engage a portion of the electronic device screen. Because of the relative thinness of ends  1302  and  1304  and sides  1306 , bezel  1300  may be strong in bending, but weaker in torsion. 
       FIG. 14  is an exploded view of the bezel of  FIG. 13  with additional components in accordance with one embodiment of the invention. Electronic device  1400  may include bezel  1300 , screen  1410 , and plate  1420  for coupling screen  1410  to bezel  1300 . Screen  1410  may include any suitable screen for providing a display to a user. For example, screen  1410  may include a liquid crystal display (LCD). Screen  1410  may be operative to be placed in aperture  1310  through the back of bezel  1300  such that at least one edge of screen  1400  abuts a portion of bezel  1300  (e.g., to prevent screen  1400  from passing through aperture  1310 ). 
     Plate  1420  may include any suitable plate for supporting screen  1410  in bezel  1300 . For example, plate  1420  may be constructed from plastic, composite materials, metal, or any other suitable material. In some embodiments, plate  1420  may be constructed from a material selected so that plate  1420  is strong in torsion, but weaker in bending. Plate  1420  may be any suitable size, including for example substantially the size of aperture  1310 , substantially the size of screen  1410 , or any other suitable size. Once plate  1420  is coupled to bezel  1300 , screen  1410  may be trapped between plate  1420  and the edges of bezel  1300 . For example, screen  1410  may be trapped between flange  1311  of bezel  1300  on one side (e.g., the side facing out of the electronic device) and plate  142  on the other side (e.g., the side facing in the electronic device), without being directly coupled to either bezel  1300  or plate  1420 . Plate  1420  may be coupled to bezel  1300  using any suitable approach. For example, plate  1420  may be coupled to bezel using an adhesive, tape, a mechanical fastener, a mechanical component (e.g., a pin), or any other suitable approach. 
     In some embodiments, plate  1420  may be coupled to bezel  1300  in a manner that increases the tortional stiffness of the assembly. For example, plate  1420  may be coupled to bezel  1300  using several mechanical fasteners (e.g., screws). To further increase the stiffness of the assembly, more fasteners than are necessary to couple the components to each other may be used. Bezel  1300  may include several screw taps  1312  operative to receive fasteners. Plate  1420  may include several holes  1422  operative to receive fasteners  1424 . Electronic device  1400  may include any suitable number of fasteners  1424 , including for example eight fasteners  1424  on each side  1306 . When fasteners  1424  are tightened, bezel  1300  and plate  1420  may be coupled and form a box-like structure or frame that is strong both in bending and in torsion.  FIG. 15  is a schematic view of the electronic device of  FIG. 14  when the electronic device is assembled in accordance with one embodiment of the invention. By coupling plate  1420  to bezel  1300 , the combined structure may increase the stiffness of screen  1410 , and may also increase the overall stiffness of electronic device  1400 . In some embodiments, plate  1420  may include one or more structures operative to receive electronic device components (e.g., electronic device components that are to be mounted on a rigid frame, such as for example a battery, a PCB, or a flex). Thus, the electronic device may include a thin assembly that is strong in both torsion and bending constructed from components that separately are not strong in both torsion and bending. 
     The electronic device bezel may have several functions. For example, one surface of the bezel may be cosmetic (e.g., the outer surface), while another surface of the bezel may be functional (e.g., the inner surface, to which electronic device components may be mounted). This may allow the electronic device to use a single component for both inner mechanical features and outer aesthetic features.  FIGS. 16 ,  17  and  18  are schematic views of a bezel of an electronic device in accordance with one embodiment of the invention. Bezel  1600  may include outer surface  1610 , which may be polished, tumbled, or otherwise finished to provide an aesthetically pleasing surface. Bezel  1600  may include inner surface  1620 , which may include several structures  1622  operative to receive one or more electronic device components (e.g., a screen, a plate, a circuit board, or a battery). For example, structures  1622  may include posts, pins, snaps, screw taps, apertures, tabs, or any other suitable structure. In some embodiments, all or substantially all of the components of the electronic device may be mounted to bezel  1600 . 
     The housing may engage the bezel using any suitable approach.  FIG. 19  is a cross-sectional view of an electronic device as a bezel is brought into contact with a housing in accordance with one embodiment of the invention. Electronic device  1900  may include housing  1910  and bezel  1930 . Bezel  1930  may include outer surface  1932  (e.g., the cosmetic surface) and inner wall  1934 . In some embodiments, inner wall  1934  may be recessed from outer surface  1932  to allow bezel  1930  to form a flush fit with housing  1910  when electronic device  1900  is assembled. Inner wall  1934  may include one or more slots  1936  operative to engage housing  1910  to close electronic device  1900 . 
     Housing  1910  may include one or more ramps  1914  operative to be coupled to inner surface  1912  of housing  1910 , where each ramp  1914  may include a latch  1916  operative to engage slot  1936  of housing  1930 . By placing ramps  1914  on the inner surface of housing  1910 , the aesthetic appeal of electronic device  1900  may be retained. Ramps  1914  may be coupled to housing  1910  using any suitable approach, including for example an adhesive, tape, hook and fastener material, a mechanical fastener, welding (e.g., spot welding or laser welding), or any other suitable approach. Ramps  1914  may follow the inner surface of housing  1910  such that ramps  1914  are operative to deflect with housing  1910 . Ramps  1914  and slots  1936  may be manufactured such that latches  1916  are aligned with slots  1936  when electronic device  1900  is assembled. 
     To assemble electronic device  1900 , bezel  1930  may be inserted into housing  1910  such that each latch  1916  may engage a slot  1936 . As inner wall  1934  passes latches  1916  and ramps  1914 , housing  1910  may deform elastically to allow inner wall  1934  to pass. In some embodiments, inner wall  1934  may be too thick or too short to deflect as it passes into housing  1910 . As shown in  FIG. 19 , housing  1910  may be progressively deformed to allow inner wall  1934  to pass (e.g., as compared to the position of housing  1910  in  FIG. 20 ) as it moves over ramp  1914 . Once bezel  1930  has been sufficiently inserted into housing  1910 , latches  1916  may reach slots  1936  and engage bezel  1930 . As latches  1916  engage slots  1936 , housing  1910  may return to its initial, un-deformed position.  FIG. 20  shows a cross-sectional view of the electronic device of  FIG. 19  once the bezel engages the housing in accordance with one embodiment of the invention. Once engaged, the outer surfaces of bezel  1930  and housing  1910  may be substantially flush. 
     The electronic device may have any suitable interface for allowing a user to provide instructions to the electronic device. In some embodiments, the electronic device may include a home button.  FIG. 21  is an exploded view of an electronic device that includes a home button in accordance with one embodiment of the invention. Electronic device  2100  may include bezel  2130  and screen  2120 . Bezel  2130  may include aperture  2132  operative to receive button  2140 . Aperture  2132  may include center hole  2133  and slots  2134  extending from the periphery of hole  2133 . Button  2140  may include flanges  2142  extending from the periphery of button  2140 . Button  2140  and aperture  2132  may be manufactured such that, when button  2140  is placed in aperture  2132 , the center of button  2140  fits in hole  2133  and flanges  2142  are placed in slots  2134 . By placing flanges  2142  in slots  2134 , button  2140  may be prevented from rotating. In some embodiments, slots  2134  may not extend all the way through the surface of bezel  2130  such that button  2140  may rest on the surface of bezel  2130 . 
     Button  2140  may be captured in bezel  2130  by placing screen  2120  over bezel  2130 . Screen  2120  may include hole  2122 , which may be substantially the same size as the center of button  2140 . Screen  2120  may not include additional openings aligned with the flanges  2142  such that, once screen  2120  is placed over bezel  2130 , button  2140  is captured between bezel  2130  and glass  2120  by flanges  2142 . In particular, button  2140  may not be directly coupled to any component of electronic device  2100 . This may reduce the number of parts required to support button  2140  as no new components specific to mounting button  2140  are introduced. 
     Button  2140  may be coupled to switch  2144  (e.g., a dome switch) to provide inputs to the electronic device circuit boards. Switch  2144  may be coupled to board  2146 , which may be located under aperture  2132  of bezel  2130 . In some embodiments, switch  2144  may be directly coupled to button  2144 , without the use of an intermediate component. 
     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: 20080904
Publication Date: 20130625
Grant Date: 20130625
Priority Date: 20070904
Inventors: DABOV TEODOR
ROTHKOPF FLETCHER R.
MANOUX PHILIPPE
Assignee: APPLE INC
CPC Classifications: [{"code": "H01Q1/243", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K9/0026", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K9/0037", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K7/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01Q1/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K9/0016", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K9/0026", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K9/0037", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K9/0016", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1633", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01Q1/42", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 40431608