PATENT DOCUMENT

Publication Number: US-9492967-B2
Application Number: US-201414254431-A
Country: US
Kind Code: B2

Title: Methods for attaching structures using heat activated thermoset film and induction heating

Abstract:
An electronic device assembly may have electronic components enclosed within plastic and/or metal housing structures. The assembly may include first and second housing structures that are joined using heat activated thermoset polymer film. The heat activated thermoset polymer film may be heated using a metal structure such as a strip or pattern of metal that is placed along or near a joint between the first and second housing structures. The temperature of the metal and associated layers of the thermoset polymer film may be raised by heating the metal using external equipment such as an induction heater. The metal layer that is heated using electromagnetic induction may be formed on the heat activated thermoset film or may be formed in or on one of the housing structures adjacent to the heat activated thermoset polymer film.

Claims:
What is claimed is: 
     
       1. A method for attaching a first structure to a second structure in a connector assembly, comprising:
 applying a metal layer to a heat activated thermoset film, wherein the metal layer comprises at least one metal trace that forms a nested loop; and 
 while the heat activated thermoset film and the metal layer are interposed between the first and second structures, induction heating the metal layer to raise the heat activated thermoset film to an elevated temperature. 
 
     
     
       2. The method defined in  claim 1  wherein the heat activated thermoset film comprises first and second layers of heat activated thermoset polymer material and wherein induction heating the metal layer comprises induction heating the metal layer between the first and second layers of heat activated thermoset polymer material. 
     
     
       3. The method defined in  claim 2  wherein applying the metal layer to the heat activated thermoset film comprises laminating the metal layer between the first and second layers of heat activated thermoset polymer material. 
     
     
       4. The method defined in  claim 1  wherein applying the metal layer to the heat activated thermoset film comprises depositing the metal layer onto the heat activated thermoset film using metal deposition equipment. 
     
     
       5. The method defined in  claim 1  wherein the metal layer comprises an iron-based material. 
     
     
       6. The method defined in  claim 1  wherein at least one of the first and second structures is formed from plastic. 
     
     
       7. The method defined in  claim 1  wherein applying a metal layer to the heat activated thermoset film comprises forming a patterned metal layer on the heat activated thermoset film to facilitate induction heating of the metal layer. 
     
     
       8. The method defined in  claim 1  wherein the first structure comprises a connector body of a connector, wherein the second structure comprises a cover structure that at least partially surrounds the connector body, and wherein induction heating the metal layer comprises induction heating the metal layer while the cover structure at least partially surrounds the connector body. 
     
     
       9. A method for attaching a first structure to a second structure, comprising:
 insert molding the first structure around a metal layer; 
 placing a heat activated thermoset film between the first structure and the second structure; and 
 while the heat activated thermoset film is interposed between the first structure and the second structure, induction heating the metal layer of the first structure to raise the heat activated thermoset film to an elevated temperature and to thereby mechanically bond the first structure to the second structure. 
 
     
     
       10. The method defined in  claim 9  wherein the first structure has a surface, wherein placing the heat activated thermoset film between the first structure and the second structure comprises placing the heat activated thermoset film on the surface, and wherein the metal layer comprises protrusions that extend from within the first structure to the surface. 
     
     
       11. The method defined in  claim 9  wherein the first structure comprises a plastic structure and wherein the plastic structure surrounds a portion of the second structure. 
     
     
       12. The method defined in  claim 11  wherein the second structure houses electrical elements and wherein induction heating the metal layer comprises induction heating the metal layer while the plastic structure surrounds the portion of the second structure. 
     
     
       13. A method for attaching a first structure to a second structure in a connector assembly, comprising:
 placing a heat activated thermoset film between the first structure and the second structure; and 
 while the heat activated thermoset film is interposed between the first structure and the second structure, induction heating a metal layer on the heat activated thermoset film to raise the heat activated thermoset film to an elevated temperature and to thereby mechanically bond the first structure to the second structure, wherein the first structure forms a connector sheath, wherein the second structure forms a connector body that is received within the connector sheath, and wherein induction heating the metal layer comprises induction heating the metal layer while the connector body is received within the connector sheath. 
 
     
     
       14. The method defined in  claim 13  wherein the first structure comprises a ring-shaped plastic structure having an inner surface, wherein the heat activated thermoset film comprises a ring-shaped heat activated thermoset film, and wherein placing the heat activated thermoset film between the first structure and the second structure comprises placing the ring-shaped heat activated thermoset film within the ring-shaped plastic structure adjacent to the inner surface. 
     
     
       15. The method defined in  claim 13  wherein the first structure comprises plastic, wherein the heat activated thermoset film is characterized by an activation temperature, and wherein induction heating the metal layer comprises induction heating the metal layer to a temperature that is above the activation temperature and that is insufficient to visibly damage the first and second structures. 
     
     
       16. The method defined in  claim 13  wherein the heat activated thermoset film comprises first and second layers of heat activated thermoset polymer material and wherein induction heating the metal layer comprises induction heating the metal layer between the first and second layers of heat activated thermoset polymer material.

Description:
BACKGROUND 
     This relates generally to electronic devices and, more particularly, to assembling components for an electronic device. 
     Electronic devices may include printed circuit boards and other internal components. A connector, for example, may include electrical wires for conveying electrical signals to and from a plurality of input-output pins on the connector. These elements may be mounted in a housing. With some devices, it may be desirable to form the housing from mating plastic housing structures. 
     Mating housing structures can be attached to each other using screws. However, screws may be unsightly. Other techniques may therefore be used that secure plastic housing structures without visible fasteners. For example, techniques for bonding plastic housing structures together such as ultrasonic welding, adhesive, and temperature bonding film may be used to avoid visible fasteners. These techniques may, however, pose manufacturing challenges. Ultrasonic welding can be used to join mating plastic parts, but may produce inconsistent results. Adhesives can be flammable, messy, and brittle. Adhesives such as cyanoacrylate adhesive can be susceptible to cosmetic defects such as blooming. Temperature bonding film (TBF), which is a low melting temperature thermoplastic polymer, may become weakened when an electronic device is operated at elevated temperatures. 
     To avoid these issues, heat activated thermoset films are sometimes used to bond housing structures of an electronic device assembly together. In a typical arrangement, the entire electronic device assembly is placed in a high temperature environment to activate the heat activated thermoset film. Many materials are not able to endure this type of high temperature environment, which limits the applications in which heat activated thermoset films can be used. 
     It would therefore be desirable to be able to provide improved ways in which to join components for an electronic device such as plastic and/or metal housing structures. 
     SUMMARY 
     An electronic device may include electronic components enclosed within a plastic housing. The electronic device may, for example, be a connector such as a data connector. The connector may include a plug having a plurality of input-output pins that electrically connect with a plurality of mating input-output pins in a mating connector port in an electronic device. 
     A connector assembly may include housing structures such as a connector body that houses electrical wires in the connector and a plastic cover structure that surrounds a portion of the connector body. The connector may be assembled by attaching the cover structure to the connector body. 
     Structures in an electronic device assembly such as first and second housing structures of a connector may be joined using heat activated thermoset polymer film. Heat activated thermoset polymer film may be heated using a metal structure such as a thin strip of metal or a patterned metal layer that is placed along or near the joint between the first and second structures. The temperature of the metal layer and associated layers of the heat activated thermoset film may be elevated by heating the metal layer using external equipment such as an induction heater. 
     In one illustrative configuration, a metal layer may be formed between first and second layers of heat activated thermoset polymer material. In another suitable configuration, a metal layer may be formed in or on one of the structures that are being attached together. For example, a first structure may be insert molded around a metal layer and the metal layer may be heated to raise the temperature of a heat activated thermoset polymer film between the first structure and a second structure. If desired, the metal layer may be attached to a surface of one of the structures using an adhesive. 
     Using induction heating to heat a metal structure within the electronic device assembly and to thereby activate a heat activated thermoset film may be advantageous as it is a non-contact heating method that only heats the desired metal structure and structures in the vicinity of the metal structure, thereby eliminating the need to place the entire device in a thermal curing oven to activate the heat activated thermoset film. Localized induction heating of an internal metal structure may also help avoid the formation of visible heat-induced artifacts such as plastic discoloration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device of the type that may have components bonded together using one or more heat activated thermoset films in accordance with an embodiment. 
         FIG. 2  is a perspective view showing how a layer of metal may be formed between first and second layers of heat activated thermoset film in accordance with an embodiment. 
         FIG. 3  is a cross-sectional side view showing how first and second components may be bonded together using heat activated thermoset film by induction heating a layer of metal between first and second layers of the heat activated thermoset film in accordance with an embodiment. 
         FIG. 4  is a cross-sectional side view showing how first and second components may be bonded together using heat activated thermoset film by induction heating metal in one of the components in accordance with an embodiment. 
         FIG. 5  is a cross-sectional side view showing how first and second components may be bonded together using heat activated thermoset film by induction heating a layer of metal on one of the components in accordance with an embodiment. 
         FIG. 6  is a cross-sectional side view showing how first and second components may be bonded together using heat activated thermoset film by induction heating metal structures on one of the components in accordance with an embodiment. 
         FIGS. 7, 8, and 9  are top views of illustrative patterns of metal traces that may be heated using electromagnetic induction to elevate the temperature of a heat activated thermoset film in accordance with an embodiment. 
         FIG. 10  is a flow chart of illustrative steps involved in bonding first and second components together using heat activated thermoset film by induction heating metal between first and second layers of heat activated thermoset film in accordance with an embodiment. 
         FIG. 11  is a flow chart of illustrative steps involved in bonding first and second components together using heat activated thermoset film by induction heating metal in or on one of the components in accordance with an embodiment. 
         FIG. 12  is a flow chart of illustrative steps involved in bonding first and second components together using heat activated thermoset film by induction heating metal parts on one of the components in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices may include structures such as plastic and/or metal housing structures. Plastic structures may be joined using ultrasonic welding, adhesives, temperature bonding film (e.g., heat activated thermoplastic film), or heat activated thermoset film. Ultrasonic welding may leave visible artifacts along a joined seam. Adhesives may be flammable and may therefore be undesirable when used in products that operate at an elevated temperature. Thermoplastic polymers may become weakened when raised to an elevated temperature during operation of an electronic device. 
     To overcome these challenges, at least some of the plastic and/or metal structures in an electronic device such as plastic and/or metal housing structures may be joined using thermoset polymers. Thermoset polymers may be raised to an elevated temperature to allow the polymer material to soften and form a bond with other materials. Unlike thermoplastic polymers, which can become soft if returned to an elevated temperature during use, thermoset polymers are generally heat resistant after they have been returned to room temperature following bonding. It may therefore be advantageous to use thermoset polymers such as heat activated thermoset films when forming bonds between respective housing structures. 
     To form a mechanical bond that attaches plastic and/or metal components to each other, heat activated thermoset polymer material can be raised to a temperature that is above the activation temperature of the thermoset polymer material (e.g., a temperature in the range of about 160-220° C.), while being sufficiently low to avoid damaging the plastic housing portions (i.e., by eliminating or at least minimizing heating of the plastic housing significantly above the glass transition temperature of the plastic housing and thereby avoiding visible damage to the plastic housing). To ensure that heat-induced artifacts such as plastic discoloration are not visible from the exterior of the device, heat may be generated from within or near the joint that is formed where the two components meet. 
     An illustrative electronic device of the type that may have plastic and/or metal components that are joined using heat activated thermoplastic film is shown in  FIG. 1 . In the example of  FIG. 1 , electronic device  10  is a connector such as a reversible data connector having a plurality of input-output pins  18 . Input-output pins  18  may be formed on a plug portion of connector  10  such as plug portion  16 . Connector  10  may have any suitable number of input-output pins  18  (e.g., 8 pins, 6 pins, 30 pins, etc.). Input-output pins  18  may be used to electrically couple connector plug  16  to a mating connector port in an electronic device (e.g., a mating female data port connector having a plurality of mating input-output pins) when plug  16  is inserted into the mating connector port. 
     Connector  10  may be coupled to a connector cable such as connector cable  12 . Connector cable  12  may be coupled to a second connector on an opposing end (e.g., a Universal Serial Bus (USB) connector or other suitable connector) and may be used to convey signals between connector  10  and the second connector on the opposing end of cable  12 . The connector on the opposing end of cable  12  (not shown) may be an independent connector plug or may be integrated with an accessory device (e.g., a memory card reader, a laptop computer, an audio speaker dock, an alternating current (AC) power adapter, etc.). Data signals and/or power supply signals may be conveyed between an electronic device and an accessory device via connector  10 , cable  12 , and a second connector on an opposing end of cable  12 . 
     Connector  10  may include plastic and metal parts. For example, connector body  44  may be used to house electrical elements in connector  10  such as electrical wires and may include plastic overmold structures and metal shielding structures for shielding the wires in connector  10 . As shown in  FIG. 1 , a protective covering structure such as polymer sheath  42  may surround a portion of connector body  44  and may be used to cover metal and/or plastic parts on connector body  44 . Polymer sheath  42  (sometimes referred to as a boot, cover structure, enclosure, or case) may have a tubular shape and may surround a portion of connector body  44  between plug portion  16  and cable  12 . 
     Cover structure  42  may be attached to connector body  44  using heat activated film such as heat activated thermoset film  48 . Heat activated thermoset film  48  may be interposed between cover structure  42  and connector body  44  and may form a mechanical bond between cover structure  42  and connector body  44 . As shown in  FIG. 1 , heat activated thermoset film  48  forms a ring-shaped structure within the ring-shaped structure formed by cover  42 . If desired, heat activated thermoset film  48  may form a mechanical bond with both metal and plastic parts on connector body  44  or may form a mechanical bond with only metal or only plastic parts on connector body  44 . 
     Heat activated thermoset film  48  may be formed from a heat activated thermoset polymer material that softens and forms a mechanical bond between components when raised to an elevated temperature (e.g., a temperature that is above the activation temperature of the thermoset polymer material such as a temperature in the range of about 160-220° C.). Unlike thermoplastic polymers, which can become soft if returned to an elevated temperature during use, thermoset polymer material  48  may be heat resistant after it is returned to room temperature following bonding. 
     The example of  FIG. 1  in which heat activated thermoset films are used to join components in a connector (e.g., cover structure  42  and connector body  44  of connector  10 ) is merely illustrative. In general, heat activated thermoset film such as film  48  may be used to join components in any suitable electronic device. For example, electronic device  10  may be 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, equipment that implements the functionality of two or more of these devices, or other electronic equipment. 
     To ensure that heat-induced artifacts such as plastic discoloration are not visible from the exterior of device  10 , heat may be generated from within or near the joint that is formed where the two components meet. For example, heat may be applied to a metal structure on or near heat activated film  48  in device  10  using electromagnetic induction. With this type of arrangement, an induction heater may be used to create an alternating magnetic field. When the metal structure is placed within the alternating magnetic field, eddy currents may be generated in the metal structure which in turn will raise the temperature of the metal structure and heat adjacent heat activated thermoset film  48 . 
     Using induction heating to heat a metal structure within device  10  and to thereby activate film  48  may be advantageous as it is a non-contact heating method that only heats the desired metal structure and components in the vicinity of the metal structure, thereby eliminating the need to place the entire device in a high temperature environment to activate film  48 . Localized induction heating of an internal metal structure may also help avoid the formation of visible heat-induced artifacts such as plastic discoloration. 
     A perspective view of an illustrative arrangement for heat activated thermoset film  48  is shown in  FIG. 2 . In the example of  FIG. 2 , heat activated thermoset film  48  includes first and second layers  48 A and  48 B of heat activated thermoset film. A layer of conductive material such as conductive material  52  may be interposed between heat activated thermoset films  48 A and  48 B to form heat activated film structure  30 . Conductive material  52  may be a layer of metal (e.g., a conductive metal foil) that has been coated onto heat activated film  48  (e.g., onto one or both of heat activated films  48 A and  48 B). If desired, conductive material  52  may be a material having a high magnetic permeability such as an iron-based material to facilitate induction heating of material  52 . 
     Coating equipment such as roller equipment may be used to roll a layer of conductive foil onto the surface of heat activated film  48 . If desired, other types of conductive materials (e.g., conductive polymers, metal silicides, etc.) may be formed between heat activated films  48 A and  48 B. Conductive material  52  may be in sheet form (e.g., aluminum foil or copper foil), may be formed from patterned metal traces, or may be a structure that is used as a substrate for one or both layers of heat activated film  48 . The use of roller-based lamination equipment to laminate metal layer  52  between heat activated films  48 A and  48 B to form structure  30  is merely illustrative. 
     Heat activated thermoset films  48 A and  48 B may, for example, be formed from a liquid precursor that is cured to form films  48 A and  48 B. The liquid precursor may be sprayed, rolled, or otherwise deposited onto the surface of a release liner or may be deposited directly on metal layer  52 . Once cured, films  48 A and  48 B may be solid at room temperature. 
     Structure  30  may be used to attach components together in an assembly. For example, heat activated film  48  of  FIG. 1  may be formed using a structure of the type shown in  FIG. 2 . With this type of arrangement, structure  30  may be wrapped to form a tubular structure that surrounds connector body  44  and that is surrounded by cover structure  42 . After inserting structure  30  between cover structure  42  and connector body  44 , an induction heater may be used to elevate the temperature of metal structure  52  using electromagnetic induction, which in turn may heat films  48 A and  48 B to thereby mechanically bond cover structure  42  to connector body  44 . 
       FIG. 3  is a cross-sectional side view showing how components such as component  44  and component  42  may be mechanically bonded together using a structure such as structure  30  of  FIG. 2 . Components  42  and  44  may be components of connector  10  of  FIG. 1  or may be components such as housing structures in another suitable assembly. As shown in  FIG. 2 , structure  30  includes metal layer  52  (e.g., a material having a high magnetic permeability such as an iron-based material) sandwiched between first heat activated thermoset film  48 A and second heat activated thermoset film  48 B. 
     An induction heater such as induction heater  50  may be used to heat metal layer  52  using electromagnetic induction. Induction heater  50  may include a power supply and having a radio-frequency signal generator that produces radio-frequency signals at a given frequency and an inductor (e.g., a copper coil) for transferring the energy from the power supply to metal layer  52 . When the power supply sends an AC current through the inductor, an alternating magnetic field is generated. When metal layer  52  is placed within this magnetic field, the temperature of metal layer  52  will rise, which in turn will elevate the temperature of heat activated films  48 A an  48 B. When the temperature of heat activated films  48 A and  48 B rises above the activation temperature, films  48 A and  48 B will soften and will form a mechanical bond between component  42  and component  44 . Heat activated films  48 A and  48 B may be characterized by an activation temperature of about 120° C. to 130° C. (or, if desired, about 100-150° C.). 
     If desired, heat activated film  48  may be heated using a metal layer  52  that has been formed in or on one or both of components  42  and  44 .  FIG. 4  is a cross-sectional side view showing an illustrative example in which metal layer  52  has been formed in component  42 . In configurations where component  42  is formed from plastic, metal layer  52  may be formed in component  42  by insert molding component  42  around metal layer  52  (as an example). 
     Metal layer  52  in component  42  may be heated using induction heater  50 . Because metal  52  is located near heat activated film  48 , the heating of metal  52  may raise the temperature of heat activated film  48  between components  42  and  44  to thereby form a mechanical bond between components  42  and  44 . 
     Metal layer  52  may be formed at the surface of plastic structure  42  (e.g., at surface  42 S of component  42  on which film  48  is formed) or may be embedded within plastic structure  42  (e.g., near surface  42 S of component  42 ). In configurations where metal layer  52  is embedded within structure  42 , metal layer  52  may include one or more protrusions such as protrusions  52 P that extend from the metal portion within plastic structure  42  to inner surface  42 S of structure  42  to reach heat activated film  48 . 
     The example of  FIG. 4  in which metal layer  52  is located in component  42  is merely illustrative. If desired, metal layer  52  may be located in component  44  or metal layers may be located in both component  42  and component  44 . 
       FIG. 5  is a cross-sectional side view showing an illustrative example in which metal layer  52  has been formed on the surface of component  44 . In the example of  FIG. 5 , metal layer  52  is attached to component  44  using an adhesive such as adhesive  46  (e.g., a pressure sensitive adhesive or other suitable adhesive). This is, however, merely illustrative. If desired, metal  52  may be deposited directly onto inner surface  44 S of component  44  using physical vapor deposition (e.g., sputtering or evaporation), electrochemical deposition, or other techniques for applying metals and other conductive materials to the surfaces of structures. 
     Heat activated film  48  may be interposed between component  42  and metal layer  52  on structure  44 . Metal layer  52  on component  44  may be heated using induction heater  50 . Because metal  52  is adjacent to heat activated film  48 , the heating of metal  52  may raise the temperature of heat activated film  48  between components  42  and  44  to thereby form a mechanical bond between components  42  and  44 . 
     In some assemblies, a component may include metal structures that are close enough to a heat activated film to be used to activate the heat activated film. For example, metal shielding structures in connector  10  of  FIG. 1  may be close enough to heat activated film  48  to be used to heat film  48 .  FIG. 6  is a cross-sectional side view showing an illustrative example in which metal structures that form part of a component in an assembly may be heated to activate a nearby heat activated film. 
     As shown in  FIG. 6 , component  44  may include metal structures such as metal structures  52 . Metal structures  52  may, for example, be used to shield electrical wires or electrical circuitry in device  10 . This is, however, merely illustrative. If desired, metal structures  52  may be metal housing structures, metal support structures, or other suitable structures in component  44 . 
     Heat activated film  48  may be interposed between component  42  and metal structures  52  on structure  44 . If desired, heat activated film  48  may be assembled with component  42  (e.g., component  42  may be a plastic component that is formed by insert molding or overmolding plastic onto film  48 ). Metal structures  52  of component  44  may be heated using induction heater  50 . Because metal  52  is adjacent to heat activated film  48 , the heating of metal  52  may raise the temperature of heat activated film  48  between components  42  and  44  to thereby form a mechanical bond between components  42  and  44 . 
     Metal layer  52  need not be formed as a solid metal strip. If desired, metal layer  52  may be patterned or may form a loop. Some shapes or patterns of metal may be more conducive to induction heating than others. If desired, the shape, size, and pattern of metal  52  may be optimized for induction heating. Illustrative patterns that may be used for metal layer  52  of  FIGS. 2, 3, 4, 5, and 6  are shown in  FIGS. 7, 8, and 9 . 
     In the example of  FIG. 7 , metal layer  52  includes two or more nested loops (e.g., two or more concentric rings) of metal traces. In the example of  FIG. 8 , metal layer  52  is formed from a single contiguous trace of metal that forms a spiral. The example of  FIGS. 7 and 8  in which the lines of metal traces  52  form rectilinear shapes are merely illustrative. If desired, metal  52  may form curved lines. For example, as shown in  FIG. 9 , metal traces  52  may include straight portions such as straight portion  52 S and meandering portions such as meandering portion  52 M. 
       FIG. 10  is a flow chart of illustrative steps involved in bonding first and second components together by induction heating metal on a heat activated thermoset film. 
     At step  100 , coating tools may be used to apply metal to a heat activated thermoset film. Coating tools may include equipment for depositing metal using physical vapor deposition (e.g., sputtering or evaporation), electrochemical deposition, or other techniques for applying metals and other conductive materials to the surfaces of dielectric structures such as film  48 . Patterns may be incorporated into metal layer during the metal deposition processes or, if desired, the metal layer may be patterned using photolithographic equipment, laser processing equipment, or other patterning equipment. If desired, coating tools may include roller equipment for rolling a layer of metal onto the layer of heat activated film. In configurations of the type shown in  FIGS. 2 and 3 , step  100  may include forming an additional layer of heat activated film over the metal layer such that the metal layer is sandwiched between the two layers of heat activated film (e.g., to form structure  30  of  FIGS. 2 and 3 ). 
     At step  102 , the heat activated thermoset film and metal assembly formed in step  100  may be placed between the first and second components. In configurations of the type shown in  FIGS. 2 and 3  in which two layers of heat activated film are used, a first heat activated film may be interposed between the metal layer and the first component, and a second heat activated film may be interposed between the metal layer and the second component. 
     At step  104 , an induction heater may generate an alternating magnetic field and the assembly formed in step  102  may be placed in the magnetic field such that the metal layer on the heat activated film is heated by electromagnetic induction. The elevated temperature of the metal layer may in turn heat the heat activated thermoset film to a temperature at or above its activation temperature. Upon heating the heat activated thermoset film to its activation temperature, the heat activated thermoset film may form a mechanical bond between the first component and the second component. 
       FIG. 11  is a flow chart of illustrative steps involved in bonding first and second components together by induction heating metal in one of the components to activate a heat activated thermoset film. 
     At step  200 , a metal layer may be formed in or on a first component. In configurations where the first component is formed from plastic, step  200  may include insert molding or overmolding the first component onto the metal layer. In another suitable configuration, the metal layer may be deposited on the surface of the first component using physical vapor deposition (e.g., sputtering or evaporation), electrochemical deposition, or other techniques for applying metals and other conductive materials to the surfaces of dielectric structures. In another suitable configuration, step  200  may include attaching the layer of metal to the surface of the first component using an adhesive (e.g., a pressure sensitive adhesive or other suitable adhesive). 
     At step  202 , a heat activated thermoset film may be placed between the first component (on which metal was formed in step  200 ) and a second component. 
     At step  204 , an induction heater may generate an alternating magnetic field and the assembly formed in step  202  may be placed in the magnetic field such that the metal layer in or on the first component is heated by electromagnetic induction. The elevated temperature of the metal layer may in turn heat the heat activated thermoset film to a temperature at or above its activation temperature. Upon heating the heat activated thermoset film to its activation temperature, the heat activated thermoset film may form a mechanical bond between the first component and the second component. 
       FIG. 12  is a flow chart of illustrative steps involved in bonding first and second components together by induction heating metal structures in or on one of the components to activate a heat activated thermoset film. 
     At step  300 , a first component may be assembled with a heat activated thermoset film. For example, in configurations where the first component is formed from plastic, step  300  may include insert molding or overmolding the first component onto the heat activated thermoset film. In another suitable configuration, step  300  may include coating the surface of the first component with a heat activated thermoset film (e.g., using spraying equipment, rolling equipment, or other suitable equipment for forming heat activated thermoset film on the surface of the first component). 
     At step  302 , the first component may be assembled with the second component. For example, in configurations of the type shown in  FIG. 1  in which the first component is a tubular cover structure and the second component is a connector body of a connector, step  302  may include sliding the tubular cover structure onto the connector body such that the cover structure covers (e.g., surrounds) a portion of the connector body. 
     At step  304 , an induction heater may generate an alternating magnetic field and the assembly formed in step  302  may be placed in the magnetic field such that metal structures on the second component are heated by electromagnetic induction. The metal structures that are heated in step  304  may, for example, be metal shielding structures, metal housing structures, metal support structures, or other metal elements that serve a purpose beyond heating the thermoset film but that are close enough to the thermoset film to elevate the temperature of the thermoset film when heated. Upon heating the heat activated thermoset film to its activation temperature, the heat activated thermoset film may form a mechanical bond between the first component and the second component. 
     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: 20140416
Publication Date: 20161115
Grant Date: 20161115
Priority Date: 20140416
Inventors: ARDISANA, II JOHN B.
JOL ERIC S.
SIAHAAN EDWARD
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C65/368", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C65/3676", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C66/61", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C66/545", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C66/50", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C65/3652", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C65/4835", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C65/5021", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C65/5057", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2101/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/36", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C65/78", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C65/3644", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C65/32", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C66/1122", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C65/3652", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C65/78", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C65/4835", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C65/3644", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2101/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C66/61", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C65/5021", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C66/545", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C65/368", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C65/5057", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C65/3676", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C66/1122", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/36", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C65/32", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C66/50", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 54321247