PATENT DOCUMENT

Publication Number: US-9547338-B2
Application Number: US-201313967595-A
Country: US
Kind Code: B2

Title: Electronic device with injection molded display trim

Abstract:
An electronic device may be provided with a display. The electronic device may include a housing. A display trim may be formed from injection molded plastic that is molded directly onto the housing. The molded plastic trim may form a rectangular ring around the periphery of the housing. The housing may have angled or curved interior surfaces that are covered by the molded plastic trim. Computer-controlled positioners may be used to center the housing within an injection molding tool. Independently controlled positioners may also be used in capturing the housing between the lower die and the upper die in the injection molding tool. The injection molding tool may inject thermoplastic elastomer material into a channel in the upper die to form the plastic display trim.

Claims:
What is claimed is: 
     
       1. A method of forming an electronic device, comprising:
 injection molding a plastic display trim having an opening onto an electronic device housing structure for the electronic device using an injection molding tool; and 
 after injection molding the plastic display trim, mounting a display in the plastic display trim by placing the display in the opening. 
 
     
     
       2. The method defined in  claim 1  wherein injection molding the plastic display trim comprises melting thermoplastic elastomer material to form plastic for the plastic display trim. 
     
     
       3. The method defined in  claim 2  wherein the injection molding tool comprises a die with a rectangular channel and wherein injection molding the plastic display trim comprises injecting the plastic into the rectangular channel. 
     
     
       4. The method defined in  claim 3  wherein the electronic device housing lies in a plane and has an angled inner surface that is angled at a non-zero angle with respect to the plane and wherein injection molding the plastic display trim comprises injection molding the plastic display trim over the angled inner surface. 
     
     
       5. The method defined in  claim 3  wherein the electronic device housing structure has a curved surface with a radius of curvature and wherein injection molding the plastic display trim comprises injection molding the plastic display trim over the curved surface. 
     
     
       6. The method defined in  claim 5  wherein the radius of curvature is more than 0.1 mm and is less than 5 mm. 
     
     
       7. The method defined in  claim 1  wherein the injection molding tool has upper die structures and lower die structures, the method further comprising:
 pressing the electronic device housing structure between the upper die structures and the lower die structures. 
 
     
     
       8. The method defined in  claim 7  further comprising:
 laterally positioning the electronic device housing structure relative to the lower die structures using computer-controlled positioners. 
 
     
     
       9. The method defined in  claim 8  wherein the lower die structures include a plurality of individually controlled sections, and wherein pressing the electronic device housing structure between the upper die structures and the lower die structures comprises moving each of the individually controlled sections against the electronic device housing structure. 
     
     
       10. The method defined in  claim 9  wherein the individually controlled sections comprise four corner sections and wherein pressing the electronic device housing structure between the upper and lower die structures comprises moving each of the four corner sections. 
     
     
       11. Apparatus, comprising:
 an electronic device housing having a ledge; 
 an overmolded plastic display trim that is injection molded onto the electronic device housing; and 
 a display within the plastic display trim, wherein the display has opposing inner and outer surfaces, wherein light is emitted through the outer surface, and wherein a portion of the plastic display trim is interposed between the inner surface of the display and the ledge of the electronic device housing. 
 
     
     
       12. The apparatus defined in  claim 11  wherein the display comprises a rectangular display cover glass mounted within the plastic display trim. 
     
     
       13. The apparatus defined in  claim 12  wherein the electronic device housing comprises a planar metal housing and wherein the overmolded plastic display trim is injection molded onto an inner surface of a peripheral portion of the planar metal housing. 
     
     
       14. The apparatus defined in  claim 11  wherein the overmolded plastic display trim has a rectangular ring shape with a rectangular opening in which the display is mounted. 
     
     
       15. The apparatus defined in  claim 14  wherein the electronic device housing lies in a plane and wherein an angled interior surface of the housing lies along an axis that is oriented at a non-zero angle with respect to the plane and wherein the overmolded plastic display trim is injected molded onto the angled interior surface. 
     
     
       16. The apparatus defined in  claim 14  wherein the electronic device housing lies in a plane and wherein a curved interior surface of the electronic device housing is characterized by a radius of curvature of more than 0.1 mm and less than 5 mm and wherein the overmolded plastic display trim is injected molded onto the curved interior surface. 
     
     
       17. The apparatus defined in  claim 14  further comprising:
 a printed circuit; and 
 electrical components mounted on the printed circuit, wherein the printed circuit and the electrical components are located between the electronic device housing and the display. 
 
     
     
       18. Apparatus, comprising:
 a metal computing device housing structure; 
 a plastic trim molded directly onto the metal computing device housing structure, wherein the metal computing device housing structure has a curved surface and wherein the plastic trim conforms to the curved surface; and 
 a display layer mounted within the plastic trim, wherein the display layer comprises opposing inner and outer surfaces joined by a side surface, wherein the curved surface of the metal computing device housing structure extends from a first portion that is parallel to the side surface of the display layer to a second portion that is parallel to the inner surface of the display layer. 
 
     
     
       19. The apparatus defined in  claim 18  wherein the display layer comprises a rectangular glass layer.

Description:
BACKGROUND 
     This relates generally to electronic devices and, more particularly, to electronic devices with displays. 
     Electronic devices often include displays. For example, cellular telephones and portable computers include displays for presenting information to users. 
     An elastomeric trim may be used when mounting a display in an electronic device. The elastomeric trim may surround the periphery of the display and may prevent the display from becoming damaged by direct contact with the housing. 
     If care is not taken, the elastomeric trim may be larger than desired. This may make it difficult or impossible to reduce the border of the display as much as desired. 
     Challenges may also arise when assembling a piece of thin trim into a device, because it may be difficult to control the orientation of the trim with respect to the structures in the device. 
     It would therefore be desirable to be able to provide improved display trims for electronic devices with displays. 
     SUMMARY 
     An electronic device may be provided with a display. The electronic device may include a housing in which the display and other components are mounted. The housing may be formed from a material such as metal, plastic, glass, or fiber-based composites. 
     A display trim may be formed from injection molded plastic that is molded directly onto the housing. An injection molding tool may heat thermoplastic elastomer pellets sufficiently to melt the plastic. Molten plastic may be formed in a desired trim shape using a channel in a mold die. 
     The molded plastic trim may form a rectangular ring around the periphery of the housing. The housing may have angled or curved interior surfaces that are covered by the molded plastic trim. 
     Computer-controlled positioners may be used to center the housing within the injection molding tool. Independently controlled positioners may also be used in capturing the housing between the lower die and the upper die in the injection molding tool. The injection molding tool may inject molten thermoplastic elastomer material into a channel in the upper die to form the plastic display trim while the lower die and upper die are pressed against the housing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a perspective view of an illustrative electronic device such as a handheld computing device in accordance with an embodiment. 
         FIG. 1B  is a perspective view of an illustrative electronic device such as a portable computer or other portable computing device with a display in accordance with an embodiment. 
         FIG. 2  is a cross-sectional side view of an illustrative electronic device with a display and display trim in accordance with an embodiment. 
         FIG. 3  is an exploded perspective view of a molding tool that may be used in forming a display trim for an electronic device display in accordance with an embodiment. 
         FIG. 4  is a perspective view of upper and lower molding dies in an illustrative molding tool having a groove in the upper die for forming an injection molded display on an electronic device housing in accordance with an embodiment. 
         FIG. 5  is a top view of a portion of a molding die having a channel with a recess for accommodating injected molded plastic for a display trim on an electronic device housing in accordance with an embodiment. 
         FIG. 6  is a cross-sectional side view of a portion of an electronic device housing showing how a molded display trim may have an angled lower surface in accordance with an embodiment. 
         FIG. 7  is a cross-sectional side view of a portion of an electronic device showing how a molded display trim may have a curved portion that is characterized by a radius of curvature in accordance with an embodiment. 
         FIG. 8  is cross-sectional side view of a portion of an electronic device showing how an illustrative molded display trim may have an angled lower surface and a curved portion that is characterized by a radius of curvature in accordance with an embodiment. 
         FIG. 9  is a perspective view of two pairs of lateral actuators that are associated with an illustrative injection molding tool for forming a molded display trim for a display in accordance with an embodiment. 
         FIG. 10  is a cross-sectional side view of an illustrative geared actuator that may be used in moving molding tool structures during the process of insert molding a display trim for a display in accordance with an embodiment. 
         FIG. 11  is a top view of an illustrative display trim molding tool in accordance with an embodiment. 
         FIG. 12  is a cross-sectional side view of an edge portion of the illustrative display trim molding tool of  FIG. 11  in accordance with an embodiment. 
         FIG. 13  is a flow chart of illustrative steps involved in forming a molded plastic display trim for an electronic device display in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Displays in electronic devices may be provided with trims. An elastomeric display trim may surround a display and prevent the display from becoming damaged by direct contact with a metal housing. For example, a display trim may prevent the display from becoming damaged by contact with a metal computing device housing or other electronic device housing structure. The display trim may be formed from plastic that is molded onto electronic device structures such as housing structures. By accurately placing the trim on the housing, tolerances may be improved, thereby allowing the size of the trim to be minimized. Difficulties that might otherwise arise when attaching a thin separate trim member to a housing can also be avoided, thereby simplifying assembly operations. 
     Illustrative electronic devices of the type that may be provided with a display and a trim for the display are shown in  FIGS. 1A and 1B . An electronic device such as electronic device  10  of  FIG. 1A  or electronic device  10  of  FIG. 1B  may be 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, equipment that implements the functionality of two or more of these devices, or other electronic equipment. In the illustrative configuration of  FIG. 1A , device  10  is a portable device such as a cellular telephone, media player, tablet computer, or other portable computing device. In the illustrative configuration of  FIG. 1B , device  10  is a portable computing device such as a portable computer having an upper housing portion with a display and a housing that is attached to the upper housing by a hinge and that contains keyboard  23  and trackpad  25 . Other configurations may be used for device  10  if desired. The examples of  FIGS. 1A and 1B  are merely illustrative. 
     Device  10  may have one or more displays such as display  14  mounted in housing structures such as housing  12 . Housing  12  of device  10 , which is sometimes referred to as a case, may be formed of materials such as plastic, glass, ceramics, carbon-fiber composites and other fiber-based composites, metal (e.g., machined aluminum, stainless steel, or other metals), other materials, or a combination of these materials. Device  10  may be formed using a unibody construction in which most or all of housing  12  is formed from a single structural element (e.g., a piece of machined metal or a piece of molded plastic) or may be formed from multiple housing structures (e.g., outer housing structures that have been mounted to internal frame elements or other internal housing structures). 
     Display  14  may be a touch sensitive display that includes a touch sensor or may be insensitive to touch. Touch sensors for display  14  may be formed from an array of capacitive touch sensor electrodes, a resistive touch array, touch sensor structures based on acoustic touch, optical touch, or force-based touch technologies, or other suitable touch sensor components. 
     Display  14  for device  10  includes display pixels formed from liquid crystal display (LCD) components or other suitable display pixel structures such as organic light-emitting diode display pixels, electrophoretic display pixels, plasma display pixels, etc. 
     A display cover layer may cover the surface of display  14  or a display layer such as a color filter layer (e.g., a layer formed from a clear substrate covered with patterned color filter elements) or other portion of a display may be used as the outermost (or nearly outermost) layer in display  14 . The outermost display layer may be formed from a transparent glass sheet, a clear plastic layer, or other transparent member. If desired, openings may be formed in the outermost layer of display  14  to accommodate components such as button  16  and speaker port  18  of  FIG. 1A  (as examples). Buttons, connector ports, and other structures may also be accommodated using openings in housing  12 . 
     The display cover layer and/or other layers in display  14  may sometimes be formed from materials such as glass, whereas housing  12  of device  10  may sometimes be formed from materials such as metal. To help prevent damage to display  14  that might otherwise arise due to direct contact between the glass or other materials in display  14  and the metal or other materials in housing  12 , a plastic (polymer) trim may be interposed between the outer edge of display  14  (i.e., the rectangular periphery of display  14 ) and the opposing inner edge of housing  12 . The trim may be formed from a plastic material that is softer than housing  12  (e.g., the trim may be formed from an elastomeric polymer). The trim may be molded onto housing  12  using injection molding (insert molding) techniques. The use of injection molding to form the trim may help in attaining tight tolerances and may simplify assembly. This may allow the size of the trim and therefore the width of the inactive border region in display  14  to be minimized, thereby enhancing device aesthetics. 
     A cross-sectional side view of an illustrative electronic device such as device  10  of  FIG. 1A  or device  10  of  FIG. 1B  taken along line  20  of  FIG. 1A  or  FIG. 1B  and viewed in direction  22  of  FIG. 1A  or  FIG. 1B  is shown in  FIG. 2 . As shown in  FIG. 2 , display trim  24  may be molded onto inner surfaces  26  of housing  12  Inner surfaces  26  may form an inwardly facing peripheral ledge that runs around the periphery of housing  12 . Display  14  may include outer display layer  30  and inner display layers  32 . Display layers such as display layer  30  or other layers in display  14  may be supported by trim  24 . In this arrangement, trim  24  may be interposed between the outer edge of display  14  and the opposing inner surface of housing  12  to help prevent damage to display  14 . 
     Outer display layer  30  of display  14  may be a layer of clear glass or plastic. For example, display layer  30  may be a display cover glass layer or other display cover layer. Layers  32  may form a liquid crystal display, an organic light-emitting diode display, a plasma display, an electrophoretic display, or other display. For example, layers  32  may include liquid crystal display layers such as a layer of liquid crystal material interposed between a color filter layer and a thin-film transistor layer and sandwiched between opposing upper and lower polarizers. If desired, the color filter layer or thin-film transistor layer may be used in place of display cover layer  30 . Configurations for display  14  in which display  14  has a display cover layer are sometimes described herein as an example. 
     Device  10  may include internal components  36  mounted on one or more substrates such as substrate  34 . Internal components  36  may include integrated circuits, sensors, switches, connectors, and other electronic components. Substrate  34  may be a printed circuit board or other substrate. For example, substrate  34  may be a rigid printed circuit board formed from a material such as fiberglass-filled epoxy or may be a flexible printed circuit board such as a flex circuit formed from a sheet of polyimide or a layer of other flexible polymer. 
     Surfaces  26  in the example of  FIG. 2  form an L-shaped ledge that supports molded trim  24 . When display  14  is mounted in device  10 , lower peripheral surface  40  of display cover layer  30  rests on surface  43  of trim  24  and outer edge surface  38  rests against surface  28  of trim  24 . Other shapes and configurations for trim  24  and housing  12  may be used if desired. The illustrative configuration of  FIG. 2  is merely illustrative. 
     Trim  24  may be formed using an injection molding tool such as tool  42  in the perspective view of  FIG. 3 . Tool  44  may have a reservoir for plastic pellets or other plastic material such as reservoir  44 . The plastic may be, for example, a thermoplastic elastomer (TPE) such as a thermoplastic polyurethane, a thermoplastic polyamide, or other thermoplastic elastomer. Reservoir  44  may be used to provide the plastic pellets to heater  46  for melting. Heater  46  may raise the temperature of the plastic pellets above their melting temperature (e.g., to a temperature of greater than 250° C.). Melted plastic may be forced into channels within a plastic molding structure such as upper die  50  through tubing  48  (as an example). 
     Upper die  50  may mate with lower die  54 . Plastic injection molding die structures such as upper die  50  and lower die  54  may be provided with alignment features such as illustrative pins  56  and mating openings  58  to help align portions of the die structures to each other and to workpiece  52 . For example, pins  56  may be used to help align upper die  50  with lower die  54 . 
     During injection molding operation, a workpiece such as workpiece  52  may be received within the die. For example, workpiece  52  may be received within a cavity in the interior of upper die  50  and/or lower die  54 , when die  50  and die  54  are joined. Workpiece  52  may be, for example, housing  12 . Upper die  50  and lower die  54  may press against the surfaces of workpiece  52  (i.e., housing  12 ) to hold workpiece  52  in place during injection molding operations. As heated molten plastic from reservoir  44  flows into the die, trim  24  can be formed directly on housing  12 . This may help trim  24  attach to housing  12  (e.g., by forming chemical bonds). The molding die may be maintained at a relatively low temperature relative to the temperature of heater  46  to help cool the plastic that forms trim  24 . For example, the molding die structures may be maintained at a temperature of about 30° C. 
       FIG. 4  is a perspective view of an illustrative set of die structures for injection molding tool  42  of  FIG. 4 . Tool  42  may have mating upper and lower injection molding die such as upper die  50  and lower die  54 . Die  50  may be formed from one or more metal members and die  54  may be formed from one or more metal members. If desired, separate sections of each die may be independently positioned using computer-controlled positioners. 
     The metal members or other structures that form the die  50  and die  54  may be pressed against the surfaces of housing  12  or other workpiece using computer-controlled positioners (actuators) to form seals that restrain the flow of molten plastic during injection molding. As shown in the example of  FIG. 4 , lower surface  62  of upper die  50  may be provided with a channel such as channel  60 . Channel  60  may have the shape of a rectangular ring-shaped groove that matches the rectangular shape of the periphery of housing  12 . Molten plastic may flow in channel  60  during molding. 
     During injection molding operations, a thermoplastic elastomer or other injection molded plastic in channel  60  may be used to form an injection molded plastic trim such as trim  24  on housing  12 .  FIG. 5  is a top view of a portion of trim channel  60  of  FIG. 4  in upper die  50  showing how channel  60  may have a locally enlarged portion such as locally enlarged portion  60 ′ to accommodate injection of molded plastic when forming trim  24 . Rectangular ring-shaped channel  60  in die  50  may be provided with one or more locally enlarged portions such as locally enlarged portion  60 ′ (e.g., one or more locally enlarged portions  60 ′, two or more locally enlarged portions  60 ′, etc.). 
       FIG. 6  is a cross-sectional side view of a portion of device  10  in a configuration in which trim  24  and housing  12  have been provided with mating angled surface  70  on the inner surface of housing  12 . Housing  12  may have a planar shape that runs parallel to horizontal axis  64  (in the orientation of  FIG. 6 ). In this configuration, the planar shape of housing  12  may lie in a horizontal plane. 
     Diagonal axis  72  may be oriented at a non-zero angle A with respect to horizontal axis  64  and the horizontal plane of housing  12 . A portion of the inner edge of housing  12  (i.e., a rectangular edge running around the rectangular periphery of housing  12  in region  70 ) may lie in a plane that runs along angled axis  72 . Trim  24  may likewise have an angled edge in region  70 . As a result, inner surface  70  of housing  12  will be angled at a non-zero angle with respect to the horizontal plane containing housing  12  and will be angled at a non-zero axis with respect to horizontal axis  64 . 
     The length of region  70  along axis  72  will be longer than the length of a horizontally oriented lower surface on trim  24 , so an angled lower surface configuration for trim  24  of the type shown in  FIG. 6  may help increase surface area in contact region  70  between trim  24  and housing  12 . The enhanced surface area in region  70  that is afforded by the non-zero angle A of axis  72  may create a large bonding surface that helps attach trim  24  securely to housing  12 . Trim  24  may also have an upper lip portion that extends over inner edge  68  of upper housing edge surface  66  to help attach molded trim  24  to housing  12 . 
     In the illustrative configuration of  FIG. 7 , region  70  of trim  24  and housing  12  is characterized by a smooth curved shape having a radius of curvature R that is greater than a minimum radius of curvature Rmin and that is less than a maximum radius of curvature Rmax. Minimum radius of curvature Rmin may be, for example, 10 mm, 5 mm, 1 mm, 0.5 mm, 0.1 mm, less than 0.1 mm, or other suitable size. Maximum radius of curvature Rmax may be 0.1 mm, 0.5 mm, 1 mm, 5 mm, 10 mm, greater than 10 mm, or other suitable size. By ensuring that the radius of curvature R is not too small, stresses in trim  24  can be minimized. Radius of curvature R is preferably not too large, so that the right angle bend between the vertical and horizontal portions of the inner surface of housing  12  can be formed compactly. 
       FIG. 8  shows how region  70  of trim  24  and housing  12  may be provided with a radius of curvature R that is between Rmin and Rmax while also orienting an extending part of region  70  along angled axis  72 . Other configurations may be used for housing  12  and trim  24  if desired. The arrangements shown in  FIGS. 6, 7, and 8  are merely illustrative. 
       FIG. 9  is a perspective view of portions of injection molding tool  42 . As shown in  FIG. 9 , injection molding tool  42  may use computer-controlled positioners (actuators) to help control the lateral position of workpiece  52  (e.g., housing  12 ) relative to upper die  50  and lower die  54  (not shown in  FIG. 9 ). For example, computer-controlled positioner  74  may use sliding member  76  to press against edge  80  of workpiece  52  in direction  78  and opposing computer-controlled positioner  82  may use sliding member  84  to press against edge  88  of workpiece  52  in direction  86 . Computer-controlled positioner  98  may use sliding member  100  to bear against surface  102  of workpiece  52  in direction  104  and opposing computer-controlled positioner  90  may use sliding structure  92  to press against edge  94  of workpiece  52  in direction  96 . More positioners or fewer positioners may be used in injection molding tool  42  if desired. For example, vertical positioners may be used at each of the four corners of workpiece  52 , combinations of vertical and horizontal (lateral) positioners may be used to adjust the position of workpiece  52 , etc. The configuration of  FIG. 9  in which two sets of opposing pairs of lateral positioners are used to adjust the lateral position of workpiece  52  is merely illustrative. 
       FIG. 10  is a diagram showing how positioners in injection molding tool  42  may have geared surfaces such as straight geared surfaces  106  on members  114  and  116  and curved geared surfaces  108  on gears  110 . Gears  110  may rotate around axes  112 . Motors attached to gears  110  or a linear actuator such as linear actuator  120  may be used in moving member  114  relative to member  116 , thereby moving sliding members or other structures in injection molding tool  42  against workpiece  52  (see, e.g.,  FIG. 9 ). 
     Housing  12  may have the shape of a rectangular box or other suitable shape. For example, housing  12  may have a rectangular box shape with curved corners, one or more curved edges, or other shapes.  FIG. 11  is a top view of injection molding equipment  42  showing how injection molding tool  42  may have a segmented lower die. As shown in  FIG. 11 , lower die  54  may have a central die portion  54 - 5  that has vacuum holes for holding workpiece  52  (housing  12 ) in place on central die portion  54 - 5 . Lower die  54  may also have four corner portions  54 - 1 ,  54 - 2 ,  54 - 3 , and  54 - 4 . The vertical position (into and out of the page in the orientation of  FIG. 11 ) of each of the portions of die  54  may be controlled independently to help ensure that the surfaces of lower die  54  conform to the exterior shape of housing  12 . In configurations in which housing  12  has curved exterior surfaces, lower die sections  54 - 1 ,  54 - 2 ,  54 - 3 ,  54 - 4 , and  54 - 5  may have mating curved surfaces that match the curved surfaces of the exterior of housing  12 . This allows lower die  54  to place pressure vertically upward on the lower surfaces of housing  12  while avoiding any damage to housing  12  (i.e., workpiece  52 ) as upper die  50  applies pressure vertically downward to form a seal when injection molding plastic for trim  24 . 
     A cross-sectional side view of an edge portion of tool  42  of  FIG. 11  taken along line  122  and viewed in direction  124  is shown in  FIG. 12 . As shown in  FIG. 12 , lower die portion  54 - 5  may have a central recess that forms a rectangular gap such as gap  130  under the center of housing  12 . Gap  130  may provide clearance between the central upper surface of lower die  54  and the outer surface of housing  12  to avoid damaging housing  12 . The upper surface of die portion  54 - 5  along the edge of housing  12  may have a curved shape that matches the curved shape of the exterior of housing  12 . Lateral positioners such as positioner  126  may be used to adjust the lateral position of housing  12  relative to lower die  54  and upper die  50 . For example, lateral positioner  126  may press against the left edge of housing  12  in direction  128  and three other lateral positioners may press against three other edges of housing  12  to allow housing  12  to be centered or otherwise positioned within tool  42 . Machine vision or other sensing techniques may be used to provide positioners in injection molding tool  42  with information on the position of dies  50  and  54  and workpiece  52 . 
     Upper die  50  may have a channel such as channel  60 . During injection molding operations, molten plastic may be injected into channel  60  to form trim  24 . As part of the injection molding process, trim  24  may form chemical bonds with mating surfaces of housing  12 . Trim  24  may also be formed with a small size that satisfies desired tight tolerances due to the use of injection molding techniques to form trim  24  directly on housing  12  while aligning housing  12  relative to the die with computer-controlled positioners. 
     A flow chart of illustrative steps involved in forming an electronic device with an injection molded plastic display trim is shown in  FIG. 13 . 
     At step  132 , housing  12  may be located into lower die  54 . Centering sliding members such as computer-controlled sliding members  76 ,  92 ,  82 , and  100  of  FIG. 9  or other lateral positioners may be used to center housing  12  within tool  42 , thereby laterally positioning housing  12  in an accurate location with respect to lower die  54 . 
     At step  136 , upper die  50  may be lowered on top of housing  12  and lower die  54 . Alignment features such as pins  56  and holes  58  of  FIG. 3  may engage with each other to align upper die  50  and channel  60  with respect to housing  12 . 
     At step  138 , lower die positioners such as independent computer-controlled vertically traveling positioners coupled to lower die portions  54 - 1 ,  54 - 2 ,  54 - 3 ,  54 - 4 , and  54 - 5  may be moved vertically upwards against the lower surfaces of housing  12  to load the lower die and thereby press the upper and lower dies together to form a seal with housing  12 . 
     At step  140 , molten plastic from heater  46  may be injected into channel  60  in upper die  50 , thereby overmolding trim  24  onto housing  12 . Trim  24  may have a rectangular ring shape or may have other suitable shapes (e.g., trim  24  may be divided into multiple trim segments, trim  24  may have straight and/or curved trim sections, etc.). 
     At step  142 , upper die  50  may be removed from housing  12 . 
     The lateral positioners of tool  42  (see, e.g.,  FIG. 9 ) may be released by moving them horizontally outward at step  144 . 
     At step  146 , housing  12  and integrally molded trim  24  may be removed from injection molding tool  24 . Trim  24  is attached to housing  12  and surrounds a rectangular opening having dimensions matching the exterior lateral dimensions of display  14 . Display  14  may be mounted in the rectangular opening in the center of trim  24  and display  14  (e.g., using a press fit, using adhesive, without using adhesive, and/or using other assembly techniques). Housing  12 , display  14 , and other components such as components  36  and substrate  34  of  FIG. 2  may be assembled together to form a completed electronic device. 
     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: 20130815
Publication Date: 20170117
Grant Date: 20170117
Priority Date: 20130815
Inventors: BERG BRUCE E.
POSNER BRYAN W.
MATHEW DINESH C.
CAO ROBERT Y.
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C45/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/3481", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2101/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/16", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29K2101/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/181", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14336", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14336", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1637", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/3481", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29D99/006", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29D99/006", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14336", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2101/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1637", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29L2031/3481", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29D99/006", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/181", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 51300886