PATENT DOCUMENT

Publication Number: US-9496602-B2
Application Number: US-201414263749-A
Country: US
Kind Code: B2

Title: Plastic electronic device structures with embedded components

Abstract:
Circuitry such as electrical components and wires and traces on flexible printed circuits can be embedded within injection-molded plastic structures. The electrical components can include integrated circuits, connectors, and system-in-package circuit modules. The system-in-package circuit modules may include components mounted on a substrate and covered with plastic. The connectors may include a connector for mating with a corresponding connector on an electronic device or a battery. The injection-molded plastic structures may form a housing. The housing may form part of an electronic device, an external case that receives an electronic device, or other structures. A near-field communications antenna may be embedded within a plastic housing. Signal wires and plastic fibers may be interlaced to form a mesh that is embedded in the plastic housing or other injection molded plastic structure.

Claims:
What is claimed is: 
     
       1. A case configured to receive an electronic device, comprising:
 a connector that mates with a corresponding connector in the electronic device; 
 an injection-molded plastic body; 
 a flexible printed circuit that is at least partially embedded within the injection-molded plastic body and that is coupled to the connector; 
 an electrical component mounted to the flexible printed circuit; and 
 a metal electromagnetic interference shield that is mounted to the flexible printed circuit and embedded within the injection-molded plastic body, wherein the metal electromagnetic interference shield surrounds and shields the electrical component. 
 
     
     
       2. The case defined in  claim 1  wherein the electrical component comprises a system-in-package circuit module. 
     
     
       3. The case defined in  claim 2  wherein the system-in-package circuit module comprises integrated circuits mounted to a substrate and enclosed in a polymer on the substrate. 
     
     
       4. The case defined in  claim 1  further comprising an additional connector having a portion that protrudes through the injection-molded plastic body and is not covered by the injection molded plastic body. 
     
     
       5. The case defined in  claim 4  wherein the additional connector is coupled to a battery connector. 
     
     
       6. The case defined in  claim 1  further comprising a near-field communications antenna embedded within the injection-molded plastic body. 
     
     
       7. The case defined in  claim 1  further comprising a flap that is coupled to the injection-molded plastic body and that rotates relative to the injection-molded plastic body. 
     
     
       8. A case configured to receive an electronic device, the case comprising:
 a plastic body; 
 a flexible printed circuit embedded within the plastic body, the flexible printed circuit comprising a flexible printed circuit connector that protrudes out of the plastic body; 
 a case connector that is electrically coupled to the flexible printed circuit, wherein the case connector protrudes from the plastic body and is configured to mate with a mating connector of the electronic device; 
 a battery comprising a battery connector that mates with the flexible printed circuit connector that protrudes out of the plastic body wherein the battery provides power to the electronic device through the case connector; and 
 an electronic component that is mounted on the flexible printed circuit and embedded within the plastic body. 
 
     
     
       9. The case defined in  claim 8  further comprising:
 an electromagnetic interference shielding structure embedded within the plastic body, wherein the electromagnetic interference shielding structure is mounted to the flexible printed circuit and surrounds the electronic component. 
 
     
     
       10. The case defined in  claim 8  further comprising:
 a near-field communications antenna embedded within the plastic body. 
 
     
     
       11. The case defined in  claim 10 , wherein the near-field communications antenna is electrically coupled to the case connector. 
     
     
       12. A case for an electronic device, the case comprising:
 a near-field communications antenna comprising a plurality of conductive loops; 
 a flexible printed circuit that is electrically coupled to the near-field communications antenna; 
 a connector that mates with a mating connector in the electronic device to couple the near-field communications antenna to the electronic device through the flexible printed circuit; 
 an electronic component mounted to the flexible printed circuit; and 
 an injection-molded plastic body that at least partially surrounds the near-field communications antenna, the flexible printed circuit, the connector, and the electronic component, wherein at least a portion of the injection-molded plastic body is interposed between the plurality of conductive loops of the near-field communications antenna. 
 
     
     
       13. The case defined in  claim 12  further comprising:
 a battery that is electrically connected to the flexible printed circuit and that provides power to the electronic device through the connector. 
 
     
     
       14. The case defined in  claim 12  further comprising:
 an additional connector that protrudes from the injection-molded plastic body.

Description:
BACKGROUND 
     This relates generally to electronic devices and, more particularly, to embedding components into plastic structures such as housings for electronic devices and external device cases. 
     Electronic devices such as computers, cellular telephones, and other electronic devices have housings. The housings are often formed from plastic. External cases such as rigid cases and foldable covers for electronic devices may also be formed from plastic. 
     It may be desirable to provide circuitry for an electronic device or external electronic device case that consumes minimal space. If the circuitry consumes too much space, an electronic device or case may become overly bulky. Unless care is taken, electronic devices and cases for electronic devices may also be unnecessarily sensitive to moisture. Device housings and external device cases often exhibit insufficient moisture resistance and are bulky. 
     It would therefore be desirable to be able to provide improved techniques for forming electronic devices and external cases. 
     SUMMARY 
     Circuitry such as electrical components and wires and traces on flexible printed circuits can be embedded within injection-molded plastic structures. The electrical components can include integrated circuits, connectors, and system-in-package circuit modules. The system-in-package circuit modules may include components mounted on a substrate and covered with molded plastic. Components may also be covered with thermoset adhesive. The connectors may include a connector for mating with a corresponding connector on an electronic device or a battery. 
     An injection-molded plastic structure may form a housing. The housing may form part of an electronic device, part of an external case that receives an electronic device, or other structure. When embedding circuitry within the injection-molded plastic structure, portions of the embedded circuitry may protrude out from the injection-molded plastic and may therefore be left uncovered by plastic. Other portions of the circuitry may be covered by the injection-molded plastic. 
     A near-field communications antenna may be embedded within a plastic housing. The near-field communications antenna may be formed from loops of wire or other signal lines. 
     Signal wires and plastic fibers may be interlaced to form a mesh that is embedded in the plastic housing or other injection molded plastic structure. The signal wires may convey signals between integrated circuits and other electrical components. These components may be mounted on flexible printed circuits having portions that are embedded within the injection-molded plastic. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device such as a laptop computer in accordance with an embodiment. 
         FIG. 2  is a perspective view of an illustrative electronic device such as a handheld electronic device in accordance with an embodiment. 
         FIG. 3  is a perspective view of an illustrative electronic device such as a tablet computer in accordance with an embodiment. 
         FIG. 4  is a perspective view of an illustrative electronic device such as a computer or other equipment with a display in accordance with an embodiment. 
         FIG. 5  is a schematic diagram of illustrative circuitry in an electronic device in accordance with an embodiment. 
         FIG. 6  is a cross-sectional side view of an illustrative electronic device in accordance with an embodiment. 
         FIG. 7  is a perspective view of an illustrative electronic device and associated external case in accordance with an embodiment. 
         FIG. 8  is a diagram showing illustrative equipment and operations involved in overmolding plastic onto electrical components and associated interconnects in accordance with an embodiment. 
         FIG. 9  is a diagram showing how component on a circuit substrate may be covered with a thermoset polymer before being embedded within an injection molded thermoplastic material in accordance with an embodiment. 
         FIG. 10  is a diagram showing how a circuit module such as a system-in-package module may be embedded within injected-molded plastic in accordance with an embodiment. 
         FIG. 11  is a cross-sectional side view of an illustrative electronic device and an associated external case showing how circuitry may be embedded within the external case in accordance with an embodiment. 
         FIG. 12  is a cross-sectional side view of an illustrative electronic device and an associated external case showing how shielding structures, connectors, and other components may be mounted within the case in accordance with an embodiment. 
         FIG. 13  is a diagram showing how signal wires may make up part of a mesh of interlaced fibers that are encased within injection molded plastic in accordance with an embodiment. 
         FIG. 14  is a top view of an illustrative injection molded plastic structure that contains a looped set of conductive lines for a near-field communications antenna in accordance with an embodiment. 
         FIG. 15  is a cross-sectional side view of an illustrative housing for an electronic device or other molded plastic structure containing an embedded near-field communications antenna such as the antenna of  FIG. 14  in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Circuitry such as signal lines and electrical components can be embedded within injection-molded plastic. The plastic may be used in forming an electronic device housing or a housing structure or other structure for an external case that receives an electronic device. The case may, for example, contain plastic walls and other structures that included embedded flexible printed circuits, wires, connectors, electronic devices, and other circuitry. 
     Illustrative electronic devices of the type that may include circuitry embedded within plastic housing walls or other plastic structures are shown in  FIGS. 1-4 . 
     Electronic device  10  of  FIG. 1  has the shape of a laptop computer and has upper housing  12 A and lower housing  12 B with components such as keyboard  16  and touchpad  18 . Device  10  has hinge structures  20  (sometimes referred to as a clutch barrel) to allow upper housing  12 A to rotate in directions  22  about rotational axis  24  relative to lower housing  12 B. Display  14  is mounted in housing  12 A. Upper housing  12 A, which may sometimes referred to as a display housing or lid, is placed in a closed position by rotating upper housing  12 A towards lower housing  12 B about rotational axis  24 . 
       FIG. 2  shows an illustrative configuration for electronic device  10  based on a handheld device such as a cellular telephone, music player, gaming device, navigation unit, or other compact device. In this type of configuration for device  10 , device  10  has opposing front and rear surfaces. A planar portion of housing  12  of device  10  may form the rear surface for device  10 . Display  14  may form the front surface of device  10 . Display  14  may have an outermost layer that includes openings for components such as button  26  and speaker port  28 . 
     In the example of  FIG. 3 , electronic device  10  is a tablet computer. In electronic device  10  of  FIG. 3 , device  10  has opposing planar front and rear surfaces. The rear surface of device  10  is formed from a planar rear wall portion of housing  12 . Curved or planar sidewalls may run around the periphery of the planar rear wall and may extend vertically upwards. Display  14  is mounted in housing  12  and forms the front surface of device  10 . As shown in  FIG. 3 , display  14  has an outermost layer with an opening to accommodate button  26 . 
       FIG. 4  shows an illustrative configuration for electronic device  10  in which device  10  is a computer display, a computer that has an integrated computer display, or a television. Display  14  is mounted on a front face of device  10  in housing  12 . With this type of arrangement, housing  12  for device  10  may be mounted on a wall or may have an optional structure such as support stand  30  to support device  10  on a flat surface such as a tabletop or desk. 
     An electronic device such as electronic device  10  of  FIGS. 1, 2, 3, and 4 , may, in general, be a computing device such as a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a media player, or other handheld or portable electronic device, a smaller device such as a wrist-watch device, a pendant device, a headphone or earpiece device, or other wearable or miniature device, a television, a computer display that does not contain an embedded computer, a gaming device, a navigation device, an embedded system such as a system in which electronic equipment with a display is mounted in a kiosk or automobile, an external case such as a cover with a flexible hinge or other cases that receives an additional electronic device, equipment that implements the functionality of two or more of these devices, or other electronic equipment. The examples of  FIGS. 1, 2, 3, and 4  are merely illustrative. 
     Device  10  may include a display such as display  14 . Display  14  may be mounted in housing  12 . Housing  12  may be formed of plastic, glass, ceramics, fiber composites, metal (e.g., stainless steel, aluminum, etc.), other suitable materials, or a combination of any two or more of these materials. Housing  12  may be formed using a unibody configuration in which some or all of housing  12  is machined or molded as a single structure or may be formed using multiple structures (e.g., an internal frame structure, one or more structures that form exterior housing surfaces, etc.). In configurations in which housing  12  is formed at least partly from a polymer such as injection molded plastic, circuitry can be embedded within housing  12 . 
     Display  14  may be a touch screen display that incorporates a layer of conductive capacitive touch sensor electrodes or other touch sensor components (e.g., resistive touch sensor components, acoustic touch sensor components, force-based touch sensor components, light-based touch sensor components, etc.) or may be a display that is not touch-sensitive. Capacitive touch screen electrodes may be formed from an array of indium tin oxide pads or other transparent conductive structures. 
     Display  14  may include an array of display pixels formed from liquid crystal display (LCD) components, an array of electrophoretic display pixels, an array of plasma display pixels, an array of organic light-emitting diode display pixels, an array of electrowetting display pixels, or display pixels based on other display technologies. 
     Display  14  may be protected using a display cover layer such as a layer of transparent glass or clear plastic. Openings may be formed in the display cover layer. For example, an opening may be formed in the display cover layer to accommodate a button, an opening may be formed in the display cover layer to accommodate a speaker port, etc. 
     A schematic diagram of an illustrative device such as devices  10  of  FIGS. 1, 2, 3, and 4  is shown in  FIG. 5 . As shown in  FIG. 5 , electronic device  10  may include control circuitry such as storage and processing circuitry  38 . Storage and processing circuitry  38  may include one or more different types of storage such as hard disk drive storage, nonvolatile memory (e.g., flash memory or other electrically-programmable-read-only memory), volatile memory (e.g., static or dynamic random-access-memory), etc. Processing circuitry in storage and processing circuitry  38  may be used in controlling the operation of device  10 . The processing circuitry may be based on a processor such as a microprocessor and other suitable integrated circuits. With one suitable arrangement, storage and processing circuitry  38  may be used to run software on device  10 , such as internet browsing applications, email applications, media playback applications, operating system functions, software for capturing and processing images, software implementing functions associated with gathering and processing sensor data such as stress data, etc. 
     Input-output circuitry  32  may be used to allow data to be supplied to device  10  and to allow data to be provided from device  10  to external devices. Input-output circuitry  32  may include wired and wireless communications circuitry  34 . Communications circuitry  34  may include radio-frequency (RF) transceiver circuitry formed from one or more integrated circuits, power amplifier circuitry, low-noise input amplifiers, passive RF components, one or more antennas, and other circuitry for handling RF wireless signals. The transceiver circuitry and antennas in communications circuitry  34  may include near-field communications transceiver circuitry (e.g., a transceiver operating at a frequency of 13.56 MHz or other suitable near-field communications frequency) and near-field communications antennas for supporting near-field communications with external equipment. 
     Input-output circuitry  32  may include input-output devices  36 . Input-output devices  36  may include devices such as buttons (see, e.g., button  26  of  FIGS. 2 and 3 ), joysticks, click wheels, scrolling wheels, a touch screen (see, e.g., display  14 ), other touch sensors such as track pads (see, e.g., track pad  18  of  FIG. 1 ), touch-sensor-based buttons, vibrators, audio components such as microphones and speakers, image capture devices such as a camera module having an image sensor and a corresponding lens system, keyboards, status-indicator lights, tone generators, key pads, strain gauges, proximity sensors, ambient light sensors, capacitive proximity sensors, light-based proximity sensors, gyroscopes, accelerometers, magnetic sensors, temperature sensors, fingerprint sensors, and other equipment for gathering input from a user or other external source and/or generating output for a user. 
     A cross-sectional side view of an illustrative electronic device such as device  10  of  FIGS. 1, 2, 3, 4, and 5  is shown in  FIG. 6 . As shown in the illustrative configuration of  FIG. 6 , device  10  may have a display such as display  14  that is mounted on the front face of device  10 . Display  14  may have a display cover layer such as cover layer  52  and a display module such as display module  50 . Display cover layer  52  may be formed from a glass or plastic layer. Display module  50  may be, for example, a liquid crystal display module or an organic light-emitting diode display layer (as examples). Display module  50  may have a rectangular outline when viewed from the front of device  10  and may be mounted in a central rectangular active area AA on the front of device  10  or may have other suitable shapes. An inactive area IA that forms a border for display  14  may surround active area AA. Opaque masking material such as black ink  54  may be used to coat the underside of cover layer  52  in inactive area IA. 
     Device  10  may include components such as components  62  that are mounted on one or more printed circuits such as printed circuit  60 . Printed circuit board  60  may have one or more layers of dielectric material and one or more layers of metal traces. Printed circuit  60  of  FIG. 6  may be a rigid printed circuit board (e.g., a printed circuit formed form a rigid printed circuit board material such as fiberglass-filled epoxy) or a flexible printed circuit (e.g., a printed circuit formed from a flexible sheet of polyimide or other flexible polymer substrate layer). Components  62  may include circuits such as the circuits of storage and processing circuitry  38  and/or input-output circuitry  32  of  FIG. 5 . Components  62  may be, for example, integrated circuits, discrete components such as capacitors, resistors, and inductors, switches, connectors, sensors, input-output devices such as status indicators lights, audio components, or other electrical and/or mechanical components for device  10 . Components  62  may be attached to printed circuit  60  using solder, welds, anisotropic conductive film or other conductive adhesives, or other conductive connections. One or more layers of patterned metal interconnects (i.e., copper traces or metal traces formed from other materials) may be formed within one or more dielectric layers in printed circuit  60  to form signal lines that route signals between components  62 . 
     If desired, device  10  may have components mounted on the underside of display cover layer  52  such as illustrative component  56  on opaque masking layer  54  in inactive area IA of device  10  of  FIG. 6 . Component  56  may be a touch sensor, a fingerprint sensor, a strain gauge sensor, a button, or other input-output device  36  (as examples). Device  10  may also have one or more connectors such as connector  76 . Connector  76  may be an audio connector, a digital data port connector, or other connector. Connector  76  may mate with a corresponding connector such as connector  72 . Connector  72  may form part of external equipment (shown schematically as structure  74 ). For example, connector  72  may be part of a cable, part of an external dock or case into which device  10  is mounted, or may be any other connector that mates with connector  76  of device  10 . 
     Device  10  may include one or more flexible printed circuits such as illustrative flexible printed circuits  64 ,  66 , and  68 . The flexible printed circuits may have layers of dielectric and layers of metal traces. The metal traces of a flexible printed circuit may be used to form signal paths to interconnect the circuitry of device  10  and/or external circuitry. For example, flexible printed circuit  64  may have signal paths that interconnect component  56  to the circuitry of components  62  on printed circuit  60 , flexible printed circuit  66  may have signal paths that couple display module  50  to components  62  on printed circuit  60 , and flexible printed circuit  68  may have signal paths for interconnecting connector  76  (which is mounted to flexible printed circuit  68 ) with the components in device  10  such as components  62 . 
     As shown in  FIG. 6 , signal paths (e.g., wires, flexible printed circuits, etc.) such as flexible printed circuit  64  can be embedded within the material that makes up housing  12 . For example, some or all of housing  12  may be made up of injection molded plastic. Flexible printed circuit  64  or other structures (e.g., wires, etc.) may be partly or fully embedded within the injection molded plastic. If desired, one or more components may be mounted on a flexible printed circuit that is embedded in plastic such as flexible printed circuit  64 . For example, component(s)  70  may be soldered to flexible printed circuit  64  or may be otherwise mounted on flexible printed circuit  64  prior to injection molding. During injection molding operations, plastic housing material for housing  12  may be injection molded over component  70  and flexible printed circuit  64  as shown in  FIG. 6 . 
     If desired, plastic may be injected molded over circuitry when forming part of a housing wall or other structure in a separate external case for device  10 . An external case may have an interior portion or other portion that is configured to receive an electronic device. When the device is installed with the case, the case can help protect the device. The case can also provide supplemental power or other features. When the case is not needed, it can be removed by a user. 
     An illustrative external case for an electronic device is shown in  FIG. 7 . As shown in  FIG. 7 , electronic device  10  may have housing  12  and connector  76 . Device  10  may have a rectangular shape or other suitable shape. In the example of  FIG. 7 , device  10  has a housing with opposing front and rear surfaces surrounded by four peripheral edges. External case  80  has a housing such as body  84 . Body  84  may have a shape that defines an inner cavity such as recess  82 . Recess  82  may have the shape of a rectangular depression that is configured to receive device  10 . For example, recess  82  may have a rectangular shape with four inner edges that mate with the four peripheral edges of housing  12  of device  10 . When device  10  is received within recess  82  or other mating structures in case  80  (e.g., structures in body member  84  of case  80  or other structures), device connector  76  may mate with a corresponding connector in case  80  such as case connector  86 . This may allow device  10  and case  80  to communicate and/or share power. For example, device  10  and case  80  can each send and receive analog and/or digital data signals through connectors  76  and  86 . Power supply signals can also flow through connectors  76  and  86 . Case  84  may, as an example, contain a power source such as a battery that supplies auxiliary power to device  10  through connectors  86  and  76 . 
     Case  80  may have an optional front flap such as flap  88 . Flap  88  may rotate about a flexible body portion or hinge that is aligned along hinge axis  92 . For example, flap  88  may be rotated about axis  92  relative to the rest of body  84  when it is desired to open flap  88  (to uncover device  10 ) or close flap  88  (to cover device  10 ). Cases such as illustrative case  80  of  FIG. 7  may sometimes be referred to as covers. Because case  80  may contain connector  86  and other circuit components, case  80  may also sometimes be referred to as an electronic device. Case  80  of  FIG. 7  has a configuration that allows case  80  to help protect device  10  from the surrounding environment. If desired, an external accessory such as case  80  may have other shapes (e.g., the shape of a dock into which device  10  can be inserted, etc.). Such external accessories may have plastic structures such as injection-molded plastic housing walls that enclose portions of connector  86  and other components. Configurations in which device  80  is an external case for device  10  are sometimes described herein as an example. 
     Fabrication equipment of the type used when embedding circuitry within plastic for device  10  or structures that are used with device  10  such as external case  80  or other equipment is shown in  FIG. 8 . 
     Initially, a flexible printed circuit such as flexible printed circuit  102  or other printed circuit may be formed using printed circuit fabrication equipment  100 . Printed circuit fabrication equipment  100  may include equipment for patterning metal traces on one or more layers of dielectric printed circuit substrate material and equipment for laminating together the layers of substrate material to form flexible printed circuit  102 . Equipment  100  may include photolithography equipment, etching equipment, printing equipment, electroplating equipment, physical vapor deposition equipment, and other equipment for patterning metal traces for signal lines onto one or more layers of material in a dielectric substrate. 
     One or more electrical components  106  may be mounted on substrate  102  using computing mounting tool  104 . Components  106  may include circuitry such as the circuitry of storage and processing circuitry  38  and the circuitry of input-output circuitry  32  of  FIG. 5 . Mounting tool  104  may include equipment for soldering components  106  to substrate  102  or other equipment for attaching components  106  to substrate  102 . 
     After printed circuit  102  has been populated with any desired components  106 , injection molding tool  108  (e.g., a heated die) may be used to injection mold plastic  110  over the upper and/or lower surfaces of printed circuit  102 , as shown in  FIG. 8 . Plastic  110  may be a thermoplastic or other suitable polymer. Plastic  110  may be injection molded into the shape of all or some of housing  12  of device  10 , all or some of body  84  of case  80 , or other suitable shape. The ability to embed interconnects such as the metal traces on flexible printed circuit  102  within plastic  110  and the ability to embed circuit components such as components  106  within plastic  110  allows the circuitry of components  106  and printed circuit  102  to be protected from moisture and helps minimize device size while potentially enhancing device aesthetics (see, e.g., printed circuit  64  of  FIG. 6 ). 
     If desired, one or more additional polymer materials may be used to cover circuitry such as printed circuit  102  and components  106 . For example, a thermoset polymer (e.g., a thermoset adhesive such as an acrylic thermoset adhesive or an epoxy thermoset adhesive) may be used in covering components  106  and a portion of printed circuit  102 . This type of arrangement is shown in  FIG. 9 . 
     Initially, flexible printed circuit  102  may be patterned and components  106  may be mounted on flexible printed circuit  102 , as described in connection with the use of printed circuit fabrication equipment  100  and component mounting tool  104  of  FIG. 8 . After components  106  have been mounted on printed circuit  102 , thermoset adhesive dispensing equipment such as tool  112  may be used to cover components  106  and/or printed circuit  102  with thermoset adhesive  114 . Thermoset adhesive dispensing tool  112  may be a nozzle or other equipment for applying adhesive  114  (e.g., by spraying, dripping, slit dispensing, molding such as injection molding, etc.). Adhesive  114  may be cured by heat applied in an oven, ultraviolet light curing, room temperature curing, or other curing techniques. 
     After components  106  and/or printed circuit  102  have been covered with thermoset adhesive  114 , injection molding tool  108  may be used to injection mold thermoplastic polymer  110  over some or all of printed circuit  102 , components  106 , and cured thermoset adhesive  114 , as described in connection with  FIG. 8 . 
       FIG. 10  shows how a system-in-package circuit module may be embedded within plastic  110 . System-in-package module  118  may be formed by mounting electrical components  106  on system-in-package substrate  122  and covering substrate  122  and components  106  with dielectric  120  (e.g., molded plastic). Electrical components  106  of system-in-package module  118  may be integrated circuits or other circuit components (e.g., circuitry such as the circuitry of  FIG. 5 ). Substrate  122  may be a rigid printed circuit board or other substrate (e.g., a substrate of plastic, ceramic, etc.). Following formation of system-in-package module  118 , module  118  may be soldered to flexible printed circuit  102  or otherwise mounted to printed circuit  102 . 
     Injection molding tool  108  may be used to cover system-in-package module  118  and/or flexible printed circuit with injection molded thermoplastic polymer  110 , as described in connection with  FIG. 8 . As with the configurations of  FIGS. 8 and 9 , plastic  110  may form part of housing  12  of device  10 , may form part of body  84  of case  80 , or may form part of other device structures. 
       FIG. 11  is a cross-sectional side view of an illustrative case and associated electronic device. As shown in  FIG. 11 , connector  76  of device  10  may have contacts (pins)  138 . Mating connector  86  have corresponding contacts (pins) such as contacts  134 . Connector  86  may be mounted to flexible printed circuit  102  so that contacts  134  are coupled to traces in flexible printed circuit  102  using coupling structures (e.g., solder and/or other conductive coupling structures, etc.). A support structure may be used in forming a protruding support member for contacts  134  and connector  86 . The support structure may be a metal or plastic member that is supported by an elastomeric support structure such as an elastomeric gasket (e.g., a silicone gasket). The gasket may be flexible to allow connector  86  to shift slightly during insertion into mating connector  76 . A metal bracket or other support structure mounted to housing  84  may be used to support the elastomeric gasket and connector  86 . 
     Body  84  of case  80  may be formed from plastic  110  that has been injection molded over flexible printed circuit  102  and components  106 . If desired, body  84  may have an outer cosmetic covering structure such as structure  124 , an inner cosmetic covering structure such as structure  126 . Structures such as structures  124  and  126  may be formed from metal members, plastic layers or injection-molded plastic structural features, pieces of metal, coating layers, fabric, or other structures. Flexible printed circuit  102  may contain signal lines that carry signals between contacts  134  on connector  86  and circuitry such as circuitry  106  on printed circuit  102  and elsewhere in case  80 . Because the circuitry of components  106  is embedded within injection-molded plastic  110 , this circuitry is shielded from moisture. Because printed circuit  102  is embedded within injection-molded plastic  110 , printed circuit  102  is shielded from moisture, consumes minimal space within case  80 , and is hidden from view by a user of case  80  and device  10 . 
     As shown in the illustrative configuration of  FIG. 12 , some of the electrical components on flexible printed circuit  102  such as component  164  may be shielded using electromagnetic interference shielding structures such as shield  150 . Shield  150  may be soldered to printed circuit  102  and may have a can shape that encloses component  164 . Shield  150  may be embedded within injection-molded plastic  110  when injection-molded plastic  110  is injection molded over printed circuit  102 . 
     Case  80  may have a battery such as battery  152 . Battery  152  may have a connector such as connector  154 . Printed circuit  102  may have a connector such as connector  156  with a portion that is embedded within injection-molded plastic  110  and a portion such as portion  158  that protrudes out of plastic  110  and is therefore not covered with plastic  110 . Connectors  156  and  154  may mate with each other so that battery  152  can supply power supply signals to printed circuit  102 . 
     Other components on printed circuit  102  may protrude out of plastic  110 , if desired. As shown in  FIG. 12 , for example, a component such as component  162  may have a portion such as portion  160  that protrudes out of plastic  110  and is therefore not covered with plastic. Component  162  may be a button, sensor, connector, or other electrical component that is soldered or otherwise mounted to printed circuit  102  (see, e.g., the components of  FIG. 5 ). Components such as component  162  and  156  may protrude out of plastic  110  in the interior of housing  84  of case  80 , may protrude through an exterior surface of housing  84 , may protrude out of an end wall or side wall of housing  84 , or may protrude out of other surfaces of housing  84 . The configuration of  FIG. 12  is merely illustrative. 
     Signals may be conveyed between electrical components  106  using wires. This type of signal path arrangement is shown in  FIG. 13 . In the example of  FIG. 13 , fibers  170  are interlaced to form a mesh. Plastic  110  may be injection molded over the mesh formed from fibers  170 . The presence of fibers  170  may help to strengthen plastic  110 . Fibers  170  may include plastic fibers, wires that do not carry signals, or other fibers that do not convey signals such as non-signal fibers  172 . Fibers  170  may also include wire (e.g., bare metal wire and/or plastic coated metal wire) such as wire  174  that serve as signal paths between electrical components  106 . Components  106  may be mounted on substrates such as illustrative printed circuit  102 . Plastic  110  may be molded over one or more of components  106  and/or some or all of printed circuit  102 , as shown in  FIG. 13 . Plastic  110  may form part of housing  12 , part of case body  84 , or other structures. During operation, wires  174  may convey electrical signals (e.g., data and/or power supply signals). Interconnects formed from metal traces on printed circuit  102  such as traces  172  may also convey signals. 
     If desired, a near-field communications antenna (e.g., an inductive loop antenna) may be embedded within plastic  110  for housing  12 , housing  84 , or other structures. This type of configuration is shown in  FIG. 14 . As shown in  FIG. 14 , near-field communications antenna  180  may be formed from one or more concentric loops of metal such as metal loops  182 . Injection-molded plastic  110  (e.g., for housing  12 , housing  84 , or other structures) may be injection molded over loops  182 , thereby embedding antenna  180  within plastic  110 . Loops  182  may be formed from metal traces on a substrate such as a printed circuit, bare metal wires, plastic coated metal wires, stamped metal foil, metal traces on a plastic carrier, or other signal paths. There may be any suitable number of loops  182  in near-field communications antenna  180 . The example of  FIG. 14  in which there are three loops in antenna  180  is merely illustrative. 
     A cross-sectional side view of an illustrative plastic structure such as the structure of  FIG. 14  taken along line  184  and viewed in direction  186  is shown in  FIG. 15 . As shown in  FIG. 15 , structure  190  may have concentric signal paths (e.g., metal wires, metal traces, etc.) such as metal lines  182  that are embedded within injection-molded plastic  110  and that form near-field communications antenna  180  (e.g., an inductive loop). Structure  190  may be a structure such as body  84  of case  80 , housing  12  of device  10 , or other device structure. 
     Structure  190  may include embedded signal paths  192 . Signal paths  192  may be formed from wires, flexible printed circuit  102 , or other signal path structures. Signal paths  192  may couple near-field antenna  180  to other circuitry in structures  190  (e.g., connector  86 , electrical components such as near-field communications transceiver circuitry and other wireless communications circuitry  34 , other circuitry of the type shown in  FIG. 5 , etc.). By embedding near-field antenna wires  182  for near-field antenna  180  in plastic  110 , near-field communications antenna  180  may be placed close to outer surface  194  of structures  190  so that signal losses in plastic  110  may be minimized. 
     The foregoing is merely illustrative and various modifications can be made by those skilled in the art without departing from the scope and spirit of the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20140428
Publication Date: 20161115
Grant Date: 20161115
Priority Date: 20140428
Inventors: KASAR DARSHAN R.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K2203/1327", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1476", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K9/0024", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01Q1/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K3/284", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2203/1316", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/09754", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2203/1327", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K9/0024", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/09754", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1316", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/284", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2203/1476", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/42", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 54319522