PATENT DOCUMENT

Publication Number: US-10437282-B2
Application Number: US-201315028847-A
Country: US
Kind Code: B2

Title: Electronic device with composite display housing

Abstract:
An electronic device may be provided with a display. The display may be mounted in a display housing having multiple display housing layers. The display housing layers may include metal layers and fiber composite layers. A fiber composite display housing layer may have an array of dimples. The fiber composite display housing layer may be attached to a planar metal layer using adhesive. An array of openings may be formed in the metal layer to lighten the display housing. A foam layer or other core may be sandwiched between display housing layers. Components may be embedded in the foam. Edge members may run along peripheral edges of the display housing layers. Electrical components may be mounted on printed circuits and housed within cavities in the display housing. The electrical components may include light-emitting diodes for a display. Heat from the electrical components may be dissipated in the metal layer.

Claims:
What is claimed is: 
     
       1. Apparatus, comprising:
 a display; 
 a display housing in which the display is mounted, wherein the display housing includes a fiber composite display housing layer with an array of depressions and a planar display housing layer that is attached to the fiber composite display housing layer; and 
 a speaker driver that passes through an opening in the fiber composite display housing layer. 
 
     
     
       2. The apparatus defined in  claim 1  wherein the planar display housing layer comprises a planar fiber composite display housing layer. 
     
     
       3. The apparatus defined in  claim 1  wherein the planar display housing layer comprises a planar metal display housing layer. 
     
     
       4. The apparatus defined in  claim 3  further comprising an electrical component that dissipates heat through the planar metal display housing layer. 
     
     
       5. The apparatus defined in  claim 4  wherein the electrical component comprises a light-emitting diode that generates light for the display. 
     
     
       6. The apparatus defined in  claim 1  further comprising core material sandwiched between the fiber composite display housing layer and the planar display housing layer. 
     
     
       7. The apparatus defined in  claim 6  wherein the core material comprises a material selected from the group consisting of: polymer, foam, a honeycomb structure, or foamed metal. 
     
     
       8. The apparatus defined in  claim 7  further comprising wires embedded within the core material. 
     
     
       9. The apparatus defined in  claim 7  further comprising hollow tubing embedded within the core material. 
     
     
       10. The apparatus defined in  claim 7  wherein the planar display housing layer has an opening, wherein a component passes through the opening, and wherein at least part of the component is embedded within the core material. 
     
     
       11. The apparatus defined in  claim 1  further comprising adhesive that attaches the fiber composite display housing layer to the planar display housing layer. 
     
     
       12. The apparatus defined in  claim 11  further comprising a plurality of openings in the planar display housing layer. 
     
     
       13. The apparatus defined in  claim 12  wherein the planar display housing layer comprises a planar metal layer and wherein the plurality of openings comprises an array of openings that lighten the planar metal layer. 
     
     
       14. The apparatus defined in  claim 1  wherein the display housing has peripheral edges, the apparatus further comprising an edge member that runs along at least one of the peripheral edges. 
     
     
       15. The apparatus defined in  claim 14  wherein the edge member comprises a metal band having a protrusion that is sandwiched between the fiber composite display housing layer and the planar display housing layer. 
     
     
       16. The apparatus defined in  claim 14  wherein the edge member is attached to the fiber composite display housing layer. 
     
     
       17. The apparatus defined in  claim 14  wherein the edge member is attached to the planar display housing layer. 
     
     
       18. The apparatus defined in  claim 14  wherein the edge member is attached to the display housing with fasteners. 
     
     
       19. The apparatus defined in  claim 14  wherein the edge member is attached to the display housing with adhesive. 
     
     
       20. The apparatus defined in  claim 1  wherein the planar display housing layer is attached to the fiber composite display housing layer with fasteners. 
     
     
       21. An electronic device, comprising:
 a display; 
 a housing in which the display is mounted, wherein the housing includes a fiber composite layer and a metal layer, wherein the fiber composite layer includes an array of depressions, and wherein adhesive attaches the fiber composite layer to the metal layer; 
 a printed circuit board mounted between the display and the fiber composite layer; and 
 an electrical component mounted on the printed circuit board. 
 
     
     
       22. The electronic device defined in  claim 21  wherein the metal layer comprises a planar metal layer. 
     
     
       23. The electronic device defined in  claim 21  further comprising a cut in each depression. 
     
     
       24. The electronic device defined in  claim 21  further comprising:
 an additional electrical component on a first surface of the metal layer; and 
 a heat spreader on an opposing surface of the metal layer that dissipates heat from the additional electrical component. 
 
     
     
       25. An electronic device, comprising:
 a display; 
 a housing in which the display is mounted, wherein the housing includes a fiber composite layer and a metal layer, wherein the fiber composite layer includes an array of depressions, and wherein adhesive attaches the fiber composite layer to the metal layer; 
 a printed circuit board mounted between the fiber composite layer and the metal layer; and 
 an electrical component mounted on the printed circuit board. 
 
     
     
       26. The electronic device defined in  claim 21  further comprising a metal member between the fiber composite layer and the metal layer. 
     
     
       27. The electronic device defined in  claim 26  further comprising a threaded hole in the metal member. 
     
     
       28. A display housing, comprising:
 a fiber composite layer having a plurality of fibers in a thermoplastic binder material; 
 a metal layer that is attached to the fiber composite layer; 
 a core layer that fills a gap between the fiber composite layer and the metal layer, wherein the fiber composite layer has an array of dimples; and 
 a mounting bracket attached to the fiber composite layer. 
 
     
     
       29. The display housing defined in  claim 28  further comprising:
 a printed circuit; and 
 an electrical component on the printed circuit, wherein the printed circuit and the electrical component are between the fiber composite layer and the metal layer and wherein the electrical component contacts the metal layer and dissipates heat into the metal layer. 
 
     
     
       30. The display housing defined in  claim 29  wherein the fiber composite layer comprises a partial height depression in one of the dimples. 
     
     
       31. The display housing defined in  claim 28  further comprising wires embedded in the core layer. 
     
     
       32. The display housing defined in  claim 28  further comprising a screw boss formed from part of the fiber composite layer. 
     
     
       33. The display housing defined in  claim 28  wherein the fiber composite layer has a portion that is configured to form a stand. 
     
     
       34. The display housing defined in  claim 28  further comprising an additional metal layer, wherein the fiber composite layer is interposed between the metal layer and the additional metal layer. 
     
     
       35. Apparatus, comprising:
 a display; and 
 a display housing in which the display is mounted, wherein the display housing has an array of depressions and includes fiber composite material, wherein the display housing has a first display housing layer in which the depressions are formed and has a second display housing layer that is attached to the first display housing layer, and wherein the fiber composite material has a plurality of fibers in a thermoplastic binder material. 
 
     
     
       36. The apparatus defined in  claim 35  wherein the second display housing layer is formed from the fiber composite material. 
     
     
       37. The apparatus defined in  claim 35  wherein the first display housing layer is formed from the fiber composite material. 
     
     
       38. The apparatus defined in  claim 35  wherein the first display housing layer is formed from metal. 
     
     
       39. The apparatus defined in  claim 35  wherein the second display housing layer is formed from metal.

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, computers, and televisions have displays. 
     It can be challenging to form displays with desired attributes. Some displays are too thick or are mounted in display housings that are too large. Other displays may be poorly integrated with electronic device components, leading to bulky designs that are not aesthetically appealing. 
     It would therefore be desirable to be able to provide electronic devices with improved display housings. 
     SUMMARY 
     An electronic device may be provided with a display. The display may be mounted in a display housing having multiple display housing layers. The display housing layers may include metal layers and fiber composite layers. A fiber composite display housing layer may have an array of dimples. The fiber composite display housing layer may be attached to a planar display housing layer such as a fiber composite layer or metal layer using adhesive. An array of openings may be formed in the planar display housing. For example, an array of diamond shaped openings may be formed in a planar metal layer to lighten the display housing. 
     A core layer may be sandwiched between the display housing layers in the display housing. The core layer may be formed from polymer foam, a solid poured in plastic resin, honeycomb material (e.g., honeycomb aramid or other honeycomb structure), expanded foamed aluminum or other foamed metal, or other materials. The core layer may be incorporated into the display housing during molding operations. Components such as electrical components on printed circuits, mechanical components such as screws, components for facilitating the formation of electrical paths such as hollow tubing, wires, and other structures may be embedded within the foam and housed within gaps between the layers of the display housing. 
     An edge member may run along peripheral edges of the display housing layers. The edge member may have portions that are sandwiched between the display housing display layers and that are attached to the display housing layers with adhesive. The edge member may be formed from metal or plastic and may be formed from one or more segments. 
     Heat may be dissipated in a metal display housing layer. A heat spreader or other heat sink structure may be used to help dissipate heat. The heat sink structure may be mounted adjacent to an electrical component that is generating heat or a metal display housing layer may be interposed between the electrical component that is generating heat and the heat sink structure. 
     The display layers may have portions that form screw bosses and other integral features. A stand for an electrical device may be formed using an integral extending portion of one of the display housing layers in a display housing. A mounting bracket may be formed from a portion of a display layer or may be attached to one of the display layers in a display housing in a location such as a depression formed in a fiber composite display layer. 
     Fiber composite display housing layers may be molded into a desired shape using a heated mold. The fiber composite display housing layers may be formed from a thermoplastic material containing carbon fibers or other fibers. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device such as a laptop computer with display housing structures in accordance with an embodiment. 
         FIG. 2  is a perspective view of an illustrative electronic device such as a handheld electronic device with display housing structures in accordance with an embodiment. 
         FIG. 3  is a perspective view of an illustrative electronic device such as a tablet computer with display housing structures in accordance with an embodiment. 
         FIG. 4  is a perspective view of an illustrative electronic device such as a display for a computer or television with display housing structures in accordance with an embodiment. 
         FIG. 5  is a cross-sectional side view of structures associated with providing a display in a display housing for an electronic device in accordance with an embodiment. 
         FIG. 6  is a cross-sectional side view of a pair of composite layers that may be used in forming a display housing in accordance with an embodiment. 
         FIG. 7  is a cross-sectional side view of illustrative layers of material including a composite layer that may be used in forming a display housing in accordance with an embodiment. 
         FIG. 8  is a perspective view of a honeycomb structure that may be used as part of a display housing in accordance with an embodiment. 
         FIG. 9  is a cross-sectional side view of an illustrative display housing structure having a core layer such as a core layer formed from a honeycomb structure in accordance with an embodiment. 
         FIG. 10  is a diagram showing how display housing structures may be formed in accordance with an embodiment. 
         FIG. 11  is a diagram of a system that uses rollers to form display housing structures in accordance with an embodiment. 
         FIG. 12  is a top view of a display housing structure having a molded composite structure and a stamped metal layer with openings in accordance with an embodiment. 
         FIG. 13  is a cross-sectional perspective view of a portion of a display housing having a molded composite layer with depressions and having a planar layer of material that is attached to the molded composite layer in accordance with an embodiment. 
         FIGS. 14, 15, 16, 17, 18, and 19  are cross-sectional side views of edge portions of a display housing in accordance with an embodiment. 
         FIG. 20  is a diagram of an illustrative electronic device with display housing structures in accordance with an embodiment. 
         FIG. 21  is a cross-sectional side view of display housing structures that are being attached to each other to form a display housing in accordance with an embodiment. 
         FIG. 22  is a cross-sectional side view of the display housing structures of  FIG. 21  in which internal cavities have been filled with a core material in accordance with an embodiment. 
         FIG. 23  is an exploded cross-sectional side view of a display having mechanical structures such as screws or other an internal features of the type that may have portions embedded within core material such as injection molded foam in accordance with an embodiment. 
         FIG. 24  is a cross-sectional side view of a display housing in which a display has been mounted in accordance with an embodiment. 
         FIG. 25  is a cross-sectional side view of a portion of a display housing wall in which a screw boss has been mounted within an opening in the display housing wall in accordance with an embodiment. 
         FIG. 26  is a cross-sectional side view of a portion of a display housing in which a screw boss has been formed by drilling through a layer in the display housing in accordance with an embodiment. 
         FIG. 27  is a cross-sectional side view of an illustrative display housing having a core material such as injection molded foam that is surrounding a buried channel such as a cable conduit or other hollow tube embedded in the foam in accordance with an embodiment. 
         FIG. 28  is an exploded side view of layers in a display housing that are being used to enclose an electrical component or other device structure in accordance with an embodiment. 
         FIG. 29  is a cross-sectional side view of a display housing having an embedded electrical component or other device structure in accordance with an embodiment. 
         FIG. 30  is a perspective view of a display housing structure in accordance with an embodiment. 
         FIG. 31  is a cross-sectional perspective view of a portion of a molded depression in a display housing layer in accordance with an embodiment. 
         FIG. 32  is a top view of an illustrative display housing layer illustrating how an array of depressions may be formed within the display housing layer in accordance with an embodiment. 
         FIG. 33  is a cross-sectional side view of display housing structures in which a cap structure has been mounted in a depression in a display housing wall in accordance with an embodiment. 
         FIG. 34  is a cross-sectional side view of display housing structures of the type that may be provided with internal cavities for mounting electronic components on printed circuit boards in accordance with an embodiment. 
         FIG. 35  is a cross-sectional side view of illustrative display housing structures having a component that dissipates heat through a thermal spreader in accordance with an embodiment. 
         FIG. 36  is a cross-sectional side view of an illustrative display housing that has been provided with a component such as a light-emitting diode that generates heat in accordance with an embodiment. 
         FIG. 37  is a cross-sectional side view of an illustrative display housing in which internally mounted components dissipate heat through layers in the display housing in accordance with an embodiment. 
         FIG. 38  is a cross-sectional side view of a depression in a display housing of the type that may be provided with internal components and half-height depression features in accordance with an embodiment. 
         FIG. 39  is a cross-sectional side view of a display housing having internal cavities for accommodating cables and other structures in accordance with an embodiment. 
         FIG. 40  is a cross-sectional side view of an illustrative display housing with a heat producing component that dissipates heat through a planar layer in the display housing and that has internal cavities in which electrical components are mounted in accordance with an embodiment. 
         FIG. 41  is a cross-sectional side view of an edge portion of a display housing having a peripheral wall member that is inserted into a peripheral gap between layers in the display housing in accordance with an embodiment. 
         FIG. 42  is a cross-sectional side view of an edge portion of a display housing having a peripheral wall member with an L-shaped cross section in accordance with an embodiment. 
         FIG. 43  is a cross-sectional side view of an illustrative display housing having a speaker or other component mounted in a display housing wall so that the speaker can use an internal air cavity formed between display housing walls in accordance with an embodiment. 
         FIG. 44  is a cross-sectional side view of an illustrative display housing having a wall mounting bracket attached to the display housing in accordance with an embodiment. 
         FIG. 45  is a cross-sectional side view of an illustrative display housing in which a display has been mounted so that circuits mounted on a substrate can be coupled to the display through an opening in a layer of the display housing in accordance with an embodiment. 
         FIG. 46  is a cross-sectional side view of an illustrative electronic device having a display housing with an integral stand in accordance with an embodiment. 
         FIG. 47  is a cross-sectional side view of an illustrative display housing having components and a display mounted on an outer surface of the display housing in accordance with an embodiment. 
         FIG. 48  is a cross-sectional side view of an edge portion of an illustrative display housing in which a peripheral member has been attached to the display housing using a fastener in accordance with an embodiment. 
         FIG. 49  is a cross-sectional side view of an edge portion of an illustrative display housing in which a peripheral member has been attached to a planar display housing layer in accordance with an embodiment. 
         FIG. 50  is a cross-sectional side view of an edge portion of an illustrative display housing in which a peripheral member has been attached to a display housing layer with an array of depressions in accordance with an embodiment. 
         FIG. 51  is a cross-sectional side view of an illustrative display housing in which a member with an array of depressions and a layer of material without depressions have been attached to each other using fasteners in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices may be provided with displays. The displays may be mounted in display housings. The display housings may form all or part of the housings of the electronic devices. Layers in the display housings may be attached using adhesive, welds, fasteners, and other attachment mechanisms. Fiber composite materials such as carbon fiber composites, fiberglass, and other materials may be used in forming one or more layers in a display housing. Fiber composite materials may have fibers that are embedded in a binder such as a thermoplastic or thermoset plastic (i.e., a polymer, sometimes referred to as a resin). Molding, machining, stamping, laser cutting, and other fabrication techniques may be used in shaping the fiber composite materials. Layers of other materials such as layers of metal may also be used in forming a display housing. 
     Illustrative electronic devices that have housings that accommodate displays are shown in  FIGS. 1, 2, 3, and 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 , housing  12  has opposing front and rear surfaces. Display  14  is mounted on a front face of housing  12 . Display  14  may have an exterior 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 , housing  12  has opposing planar front and rear surfaces. Display  14  is mounted on the front surface of housing  12 . As shown in  FIG. 3 , display  14  has an external 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 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 table top or desk. 
     In devices such as devices  10  of  FIGS. 1, 2, 3, and 4 , housing  12  receives display  14  and therefore serves as a display housing for display  14 . To enhance device aesthetics and performance, it may be desirable to form some of the display housing of device  10  (e.g., housing  12  of  FIGS. 1, 2, 3, and 4 ) from fiber composites, metal, and/or material that is sandwiched together between layers of fiber composite material and/or metal to form thin, stiff, and lightweight structures of the type that can be used to support flat panel displays. By forming sandwiches of appropriate materials, weight can be minimized, stiffness can be enhanced, and internal structures such as embedded components can be accommodated. 
       FIG. 5  is a cross-sectional side view of structures associated with supporting and housing a display in electronic device  10 . As shown in  FIG. 5 , display  14  may be mounted to display housing structures such as display housing layers  34 . Display  14  may be a liquid crystal display, an organic light-emitting diode display, a plasma display, an electrophoretic display, a display that is insensitive to touch, a touch sensitive display that incorporates and array of capacitive touch sensor electrodes or other touch sensor structures, or may be any other type of suitable display. 
     Display housing layers  34  may include layers that are formed from carbon-fiber composite material, fiberglass composite material, or other fiber composites, metal, plastic, glass, ceramic, or other materials. Display housing layers  34  may be attached to one another using layers of adhesive (e.g., pressure sensitive adhesive, liquid adhesive, etc.), fasteners such as screws, engagement features (e.g., clips and springs, etc.), magnets, or other suitable attachment mechanisms. 
     In some configurations, display housing layers  34  use a sandwich construction to form relatively thin and rigid structures for supporting display  14 . With this type of configuration, layers  34  may include, for example, one or more planar layers of metal, plastic, fiber composite, glass, ceramic, paper, or combinations of these materials, one or more layers of these materials with dimples or other depressions (e.g., layers with an array of depressions or other indentations for enhancing stiffness), and one or more core layers (e.g., foam such as injection molded foam, honeycomb structures, etc.). Fabrication techniques such as machining, stamping, cutting, molding, injection molding, laminating, and other fabrication techniques may be used in forming a display housing from layers  34  to house display  14  in device  10 . In some of these techniques, sandwich structures are formed in which one more layers are attached to one another to form a display housing. 
       FIG. 6  is a cross-sectional side view of an illustrative sandwich structure for a display housing in device  10 . As shown in  FIG. 6 , display housing  12  may include core layer  36  sandwiched between layers  34 . Layers  34  may be, for example, fiber composite layers having fibers  40  embedded in binder  38 . Fibers  40  may be carbon fibers, glass fibers, or other types of fiber. Binder  38  may be a polymer such as a thermoset plastic or a thermoplastic plastic. Layers  34  may be shaped into a desired shape by application of heat and pressure in a heated mold or may be machined or otherwise shaped into a desired configuration. Core material  36  may be foam (e.g., plastic foam), honeycomb material, or other material. If desired, air may fill some or all of the spaces between layers  34  (i.e., layers  34  may enclose air-filled cavities in display housing  12 ). In a typical configuration, one of layers  34  (e.g., layer  34 A) may serve as a mounting layer for display  14  (sometimes referred to as a front layer or inner layer) and another of layers  34  (e.g., layer  34 B) may serve as a cosmetic surface (sometimes referred to as a rear layer or outer layer). 
       FIG. 7  is a cross-sectional side view of display housing  12  in an illustrative configuration in which front layer  34 A has been formed from fiber composite material and rear layer  34 B has been formed from a different type of material (e.g., plastic, glass, metal, multiple sandwiched layers, etc.) 
       FIG. 8  is a perspective view of a honeycomb structure that may be used as part of display housing. The structure of  FIG. 8  may, for example, be used in forming core  36 . 
       FIG. 9  is a cross-sectional side view of an illustrative display housing structure with a core such as honeycomb structure  36  of  FIG. 8  sandwiched between respective display housing layers  34 . 
     Display housing  12  may be formed using equipment of the type shown in  FIG. 10 . Initially, layer  40  may be processed using fabrication equipment  42  to form display housing layer  34 ′. Layer  40  may, for example, be formed from metal, glass, plastic, ceramic, fiber composite material, etc. Fabrication equipment  42  may include machining equipment, cutting equipment (e.g., equipment that includes a blade, a rotating cutting head, water-jet cutting equipment, a laser cutting head, etc.), stamping equipment (e.g., a die for stamping metal or plastic sheets into a desired shape), or other equipment for processing layer  40  to produce a desired shape for display housing layer  34 ′. If desired, layer  32 ′ may be formed using molding equipment and machining tools  44 . For example, layer  32 ′ may be formed from a layer of plastic or fiber composite material containing a thermoplastic binder material that is molded to a desired shape using a heated die. Optional cutting, machining, and other fabrication operations may be performed on the molded layer to form display housing layer  34 ′. 
     Equipment such as molding and machining equipment  46  may likewise be used in forming one or more display housing layers such as layer  34 ″. Layers  34 ′ and/or  34 ″ may have dimples or other depressions or surface features (see, e.g., depressions  54 , which may sometimes be referred to as protrusions, indentations, or cavities). 
     Bonding equipment  48  may attach layers  34 ′ and  34 ″ together using connections  50 . Bonding equipment  48  may include equipment for dispensing a sheet of pressure sensitive adhesive, liquid adhesive, solder, fasteners, or other material. Equipment  48  may form welds or other connections structures if desired. Connections  50  may be adhesive, solder, welds, screws or other fasteners, etc. 
     Assembly equipment  52  may be used to mount display  14  within display housing  12  and to complete assembly of device  10 . Equipment  52  may perform these assembly operations using adhesive, fasteners, and other attachment structures. 
     In the illustrative example of  FIG. 11 , roll feeder equipment  70  uses rollers  60  to create a sandwich of layers  62  and  64 . Layer  64  may be, for example, a core layer of foam or honeycomb material (as an example). Layers  62  may be fiber composite layers such as carbon fiber composite layers or layers of fiberglass (as an example). Thin metal layers may also be used for layers  62 . Cutting tool  66  may cut the layer of sandwiched material  34  that is produced by equipment  70  into individual panels. Robotic equipment that is associated with tool  66  may help transfer the cut panels of material from system  70  to heated mold (press)  68 . If desired, layers  34  may be preheated to facilitate molding in tool  68 . Tool  68  may be a low pressure tool that deforms foam layer  64  while molding heated composite layers  62  (e.g., while heating and molding thermoplastic material in layers  62 ) into a desired shape. The shape in which tool  68  deforms layers  62  may have an array of depressions  54  to help strengthen display housing  12 . 
     If desired, display housing  12  may be formed from a metal layer or other layer  34  with openings. This type of configuration is shown in  FIG. 12 . As shown in  FIG. 12 , display housing  12  may include two layers  34 . One layer may be a metal layer with a two-dimensional array of diamond-shaped holes or other openings  72 . The array of openings  72  may have any suitable number of rows and columns (e.g., two or more, five or more, ten or more, etc.). The use of openings  72  may accommodate components and wiring in display housing  12  and/or may reduce the weight associated with display housing  12 . 
     A metal layer that is used as a display housing layer in display housing  12  may serve as a heat sink and ground plane for display housing  12 . Non-metal layers in display housing  12  may be formed from molded composite material and may have integral features such as recesses  74  (sometimes referred to as depressions, indentations, etc.). Recesses  74  may be configured to receive electrical components and other device structures. The use of composite material for one of the layers  34  of display housing  12  may help provide display housing  12  with stiffness, strength, and the ability to provide recesses and other features of desired shapes. If desired, the layer of display housing  12  that includes the recesses and other features may be a metal layer and the layer of display housing  12  that provides strength may be a planar composite layer. Combinations of these types of arrangements and display housing configurations with three or more display housing layers may also be used. 
       FIG. 13  is a perspective view of an illustrative configuration that may be used for display housing  12 . Display housing  12  may include metal layer  34 M and composite layer  34 C. Recesses  74  may be used to accommodate components and other structures in display housing  12 . In some embodiments (e.g., scenarios in which recesses  74  form an array of dimples), the shapes of the depressions formed from recesses  74  may provide additional strength to housing  12  by making the display layer less flexible and enhancing torsional rigidity. Additional strength may be provided by filling the cavities between layer  34 C and layer  34 M with foam  78  or other strengthening core material. Openings such as opening  76  may be formed in layer  34 C to accommodate wiring and other structures in device  10  (e.g., to accommodate cables or other wires that extend between recess  74  and components embedded within foam  78 ). 
     The edges of display housing  12  may be provided with strips of metal, plastic, or other protective edge members. These edge member(s), which may sometimes be referred to as band structures or a housing band, may be formed in segments (e.g., four elongated segments that extend along each of the four sides of display housing  12  in a configuration in which display housing  12  has a rectangular footprint to accommodate a rectangular display) or may be formed in other shapes (e.g., a unitary rectangular ring having a rectangular opening to receive layers  34 ), etc. 
     In the illustrative cross-sectional side view of the edge portions of display housing  12  of  FIG. 14 , inwardly directed edge member protrusion  80 P of edge member  80  is attached (sandwiched) between respective layers  34 . Layers  34  may be separated by a layer of core material such as core material  36  (e.g., foam, etc.). 
     In the configuration of  FIG. 15 , protrusion  80 P of edge member  80  has channels  80 C to provide a mechanical locking feature that helps retain edge member within display housing  12 . 
     In the example of  FIG. 16 , low durometer elastomeric gasket  82  is used to allow for expansion and contraction of the structures of  FIG. 16  due to changes in temperature. The configuration of  FIG. 16  can accommodate mismatches in the coefficient of thermal expansion between the materials in different display layers  34 . 
       FIG. 17  shows how one of layers  34  may be folded downwards to meet the other of layers  34  and how an attachment structure such as strip  84  may help attach protrusion  80 P of edge member  80  to layers  34  of display housing  12 . This design allows for separation of edge member  80  from layers  34 . Strip  84  may be attached using adhesive or other attachment mechanisms (e.g., strip  84  may be attached after attaching member  80  to the display housing). Strip  84  may be formed from fiber composite material or other materials (e.g., plastic, metal, etc.). 
       FIG. 18  is a cross-sectional side view of an edge portion of illustrative display housing structures  12  in which a C-shaped closeout (structure  86 ) allows for attachment of edge member  80  after forming an initial subassembly by sandwiching foam layer  36  between layers  34 . Initially, structure  86  is mounted along the edge of layers  34  and  36 . After successful attachment of structure  86 , edge member  80  may be added to display housing  12  by inserting protrusion  80 P into the opening formed by C-shaped structure  86 . The use of a closeout structure such as illustrative closeout structure  86  may help form a seal that isolates foam  36  from the ambient environment. Foam  36  may be a hydrophilic foams such as expanded polyurethane, so environmental sealing may help form an air barrier that prevents moisture from infiltrating foam  36 . 
     As shown in  FIG. 19 , the edge of display housing  12  may be folded back on itself to form a curved outer surface such as curved surface  88  (e.g., to allow for a rear cover composite design). 
       FIG. 20  is a diagram of illustrative display housing structures  12  formed by attaching four respective edge member segments  80 - 1 ,  80 - 2 ,  80 - 3 , and  80 - 4  to planar housing structure  90 . Structure  90  may be formed by sandwiching core  36  between layers  34  and providing an edge structure of the type shown in the examples of  FIGS. 14, 15, 16, 17, 18 , and  19  (as examples). Lower edge member segment  80 - 4  may have a protrusion such as tab (tongue)  92  that is received within edge recess  94  of panel  90  (e.g., to provide additional strength to member  80 - 4  to facilitate integration with a hinge, stand, or other housing structures). Edge members  80  (e.g., segments  80 - 1 ,  80 - 2 ,  80 - 3 , and  80 - 4  in the example of  FIG. 20 ) may be formed from a metal such as stainless steel or aluminum, from plastic, or from other materials. 
       FIG. 21  is a cross-sectional side view of display layers  34  that are being attached to each other with a peripheral ring of adhesive  96  (e.g., a strip of adhesive that runs along one or more of the edges of layers  34 ) and one or more lengths of edge member  80  (e.g., an edge member that runs along one or more of the edges of layers  34 ). Openings such as illustrative opening  98  may be provided in one or more of layers  34  to accommodate injection of core material  36  into the cavity formed between layers  34 , as shown in  FIG. 22 . Core material  36  may be polymer foam, plastic resin, or other materials (e.g., honeycomb material such as honeycomb aramid, expanded foamed aluminum, or other materials). 
     With a configuration of the type shown in  FIGS. 21 and 22 , layers  34  may be formed separately and subsequently glued together using adhesive  96 . This type of approach allows potentially complicated device structures (e.g., plastic and/or metal features) to be incorporated into device housing  12 . As shown in  FIG. 23 , for example, mechanical structure  100  (e.g., a screw, screw boss, other mechanical fasteners, mounting bracket, or other structure) may have portions on the inside and on the outside of the cavity formed between respective display housing layers  34 . Layers  34  may be formed separately. An opening may be drilled in one (or both) of layers  34  to accommodate attachment of structure  100 . Structure  100  can then be attached in the opening (e.g., a nut may be screwed onto a threaded shaft in structure  100 ). Adhesive  96  can be compressed between layers  34  by joining layers  34  in directions  102 . By filling the interior of display structures  12  between layers  34  with foam  36 , structures  100  may be at least partly embedded within foam  36 . In this way, structures  100  may be captured by and thereby secured by the foam to enhance strength and electrical insulation. 
       FIG. 24  is a cross-sectional side view of display housing  12  in a configuration in which display  14  has been mounted to one of layers  34 . Layers  34  may, as an example, include a planar layer (the uppermost layer in the orientation of  FIG. 24 ) and a layer with an array of recesses  54 . Recesses  54 , which may sometimes be referred to as depressions, indentations, recesses, protrusions, dimples, cavities, etc. may be provided in a two dimensional array that covers the lowermost layer of housing  12  (in the orientation of  FIG. 24 ). Edge member  80  may be attached between layers  34  using adhesive  96 . Core  36  (e.g., foam) may be sandwiched between layers  34 . Adhesive or other attachment mechanisms may be used to secure the structures of display  14  within display housing  12 . For example, adhesive may be interposed between display  14  and the adjacent layer  34  in display housing  12 . 
     As shown in  FIG. 25 , layers  34  may have openings such as opening  104 . Components such as screw boss structure  106  may be mounted in openings such as opening  104  (e.g., using adhesive). Screw boss  106  may include threaded opening  108  to receive a threaded screw. 
     In the example of  FIG. 26 , a screw boss has been formed by sandwiching screw boss member  106  between layers  34 . In this type of configuration, a drill may be used to drill directly through one of layers  34  when forming threaded screw hole  108 . Screw boss structures such as structures  106  of  FIG. 26  may be formed from metal, plastic, or other material. 
     If desired, hollow tubes and other conduit structures may be embedded within core  36  between layers  34 . As shown in  FIG. 27 , for example, one or more tubes such as hollow tube  110  may be embedded within core  36  between respective display housing layers  34 . Interior portion  112  of tube  110  may be filled with air. This allows structures such as wires  114  or other electronic components and structures in device  10  to be routed through interior portion  112 . Wires  114  may carry power, analog data signals, digital data signals, optical signals (e.g., when cables  114  are formed from optical fiber), etc. If desired, wires  114  may be directly embedded within core material such as foam  36 . 
       FIG. 28  is an exploded side view of layers  34  in display housing  12  that are being used to enclose illustrative structure  116 . Structure  116  may be hollow tubing, an electrical component, a housing structure, a screw boss structure, wires, or other device structure. 
     After sandwiching together display housing layers  34  and injecting foam  36  into the cavities formed between display housing layers  34  (e.g., cavities formed by depressions  54 ), display housing layers  12  of  FIG. 28  may appear as shown in  FIG. 29 . 
       FIG. 30  is a cross-sectional perspective view of display housing  12  taken along a line that bisects a plurality of depressions  54  in one of display housing layers  34 . Adhesive, fasteners, or other attachment mechanisms may be used in attaching layers  34  together. Depressions  54  may form a two-dimensional array having a plurality of rows and columns. The presence of depressions in a display layer stiffens the layer and thereby helps stiffen display housing  12 . 
       FIG. 31  is a cross-sectional perspective view of a portion of depression  54  showing how cross-shaped cuts  118  or other openings may be formed in each depression  54  to prevent damage to layer  34  in a scenario in which layer  34  is formed from a fiber composite that is resistant to stretching (e.g., carbon fiber composite). Cuts  118  may help depressions  54  to be successfully formed (i.e., cuts  118  may help accommodate stretching in the material in depressions  54 ) while molding composite layers  34 C to form display housing  12 . 
       FIG. 32  shows how display housing  12  may have a plurality of depressions  54  arranged in an array. Depressions  54  may have circular footprints (i.e., circular shapes when viewed from above), may have oval shapes, may have rectangular or square shapes, or may have other shapes with curved and/or straight edges. The example of  FIG. 32  in which depressions  54  have oval footprints is merely illustrative. 
       FIG. 33  is a cross-sectional side view of display housing  12  in a configuration in which a cap structure has been mounted in depression  54 . In particular printed circuit board  120  or a layer of metal or plastic may be used in forming the cap structure. Components  122  may be mounted on printed circuit board  120  so that components  122  are mounted within the available space provided by depression  54  in display housing layer  34 . Air may be used to cool components  122  during operation. 
     As shown by the cross-sectional side view of  FIG. 34 , components  122  may protrude towards display  14 . Display  14  may be mounted adjacent to a display layer with depressions  54  for accommodating printed circuit board  120  and components  122 . Edge members  80  may be attached to the edges of display housing structures  12  between display  14  and an adjacent one of layers  34 . In this configuration, one of layers  34  (i.e., the layer  34  with depressions  54 ) is interposed between the other of layers  34  (e.g., the planar layer) and display  14 . Configurations in which display  14  is mounted adjacent to a planar display housing layer (also referred to herein as a planar metal layer, a planar metal display housing layer, a planar layer, and a planar composite layer) and in which the planar display housing layer is interposed between display  14  and the display housing layer with depressions  54  may also be used. 
     Some components  122  may generate heat. Heat that is produced during operation may be dissipated through layers  34 . For example, layers  34  include a metal layer such as an aluminum layer and components  122  may dissipate heat through the metal layer. In the example of  FIG. 35 , component  122  has been mounted to a planar metal layer  34 PM that is in turn attached to a display housing layer  34  with depressions  54 . Heat spreader  124  has been mounted in one of depressions  54  to help dissipate heat generated from component  122 . The metal layer  34 PM on which spreader  124  is mounted has opposing first and second surfaces. Spreader  124  is mounted on the first surface and component  122  is mounted on the opposing second surface. Because heat spreader  124  has been mounted in a cavity formed by one of depressions  54 , heat spreader  124  can be incorporated into display housing  12  without making display housing  12  too bulky. Heat spreader  124  may be formed from metal, may be a graphite heat spreader, may be a graphene heat spreader, or may be formed form other heat sink materials. 
     In the example of  FIG. 36 , heat spreader  124  is mounted on the same side of display housing layer  34  as component  122 . Heat spreader  124  may be, for example, a graphite heat spreader, a graphene heat spreader, or a metal heat spreader such as a heat spreader formed from aluminum. The lower layer  34  in  FIG. 36  may be a planar metal layer such as a layer of aluminum. The upper layer  34  in  FIG. 36  may be a composite layer (also referred to herein as a fiber composite layer and a fiber composite display housing layer) such as a layer of carbon fiber material. Display  14  may be a liquid crystal display (e.g., a display in which component  122  is a light-emitting diode that generates backlight for a backlight unit associated with display  14 ), an organic light-emitting diode display, or other display. 
       FIG. 37  is a cross-sectional side view of an illustrative configuration for display housing  12  in which components  122  have been mounted on printed circuit boards  120 . Lower display housing layer  34  may be a layer of carbon fiber material or other fiber composite material with an array of depressions  54 . Printed circuit boards  120  and components  122  may be mounted on one or both sides of the lower display housing layer  34 . Upper display housing layer  34  may be a layer of metal such as a layer of aluminum suitable for dissipating heat that is generated by components in device  10 . As shown in  FIG. 37 , component  122 A has been mounted so as to contact (directly or through thermal grease) upper display housing layer  34  (i.e., the display housing layer  34  that is adjacent to display  14 ). This help transfer heat from component  122 A to layer  34  during operation to cool component  122 A. Component  122 B may likewise dissipate heat into upper (metal) layer  34  via printed circuit board  120 , which is mounted in contact with upper layer  34 . 
     Recesses such as depressions  54  in display layers  34  may be used to form air filled cavities. In the example of  FIG. 38 , the uppermost display layer  34  (in the orientation of  FIG. 38 ) is formed from a fiber composite material and has depression  54 . The lowermost display layer  34  is formed from metal or other material. Optional half-height (non-full-height) depressions  54 HH may be formed in within depression  54  in uppermost display layer  34  to help strengthen this layer within recess  54 . Air may fill the cavity formed between cap  130  and the portions of uppermost display layer  34  adjacent to depression  54 . Component  122  may be mounted in the cavity. The air of the cavity may cool component  122 . If desired, component  122  may be a speaker (i.e., a speaker driver) that uses the cavity formed from depression  54  as a speaker box. 
       FIG. 39  shows how a screw boss such as screw boss  132  may be formed as an integral portion of one of display housing walls  34  (i.e., the uppermost wall  34  in the orientation of  FIG. 39 ). A metal insert may be incorporated into the screw boss structure if desired. Display  14  may be mounted adjacent to uppermost wall  34 . Wires  114  or other components may be embedded within foam core  36 . If desired, wires  114  may be routed through embedded hollow tubes. Screw  134  may have a threaded shaft that is received within mating threads in screw boss  132  of uppermost wall  34 . 
       FIG. 40  is a cross-sectional side view of illustrative display housing  12  in a configuration in which heat producing components  122  are mounted within recesses  54 . Display housing  12  may include uppermost display housing layer  34  and lowermost display housing layer  34  (in the orientation of  FIG. 40 ). The lowermost display housing layer  34  may be a layer of metal such as a layer of aluminum that helps dissipate heat from components. The lowermost display housing layer  34  of display housing  12  of  FIG. 40  may, for example, dissipate heat  136  from component  122 B (e.g., a light-emitting diode for a liquid crystal display such as display  14 ). The uppermost display housing layer  34  may be a fiber composite layer that has depressions  54  and that is interposed between lowermost display housing layer  34  and display  14 . 
       FIG. 41  is a cross-sectional side view of an edge portion of display housing  12  in a configuration in which a depression  54  forms a cavity adjacent to edge member  80 . Edge member  80  may have an inwardly protruding portion such as protrusion  80 P that is attached between opposing display housing layers  34  using adhesive  96 . The cavity formed from depression  54  may contain components and device structures. For example, wires  114  may be routed within the cavity. The display housing layer  34  that includes depressions  54  (i.e., uppermost layer  34  in  FIG. 41 ) may be formed from carbon fiber material or other fiber composite material and the planar display housing layer  34 P (i.e., lowermost layer  34  in  FIG. 41 ) may be formed from a metal such as aluminum). 
     If desired, edge member  80  may have an L-shaped cross-sectional shape. This type of arrangement is shown in  FIG. 42 . Layers  34  may be attached to each other using adhesive  96 . Adhesive  96  may also be used in attaching L-shaped edge member  80  to the peripheral edge of display housing  12 . 
       FIG. 43  is a cross-sectional side view of an illustrative configuration for display housing  12  in which speaker driver  140  is mounted in an opening in one of display housing layers  34  (e.g., a fiber composite layer with a depression  54  that forms an air-filled cavity). The cavity formed by depression  54  and the portion of the planar display housing layer  34 P that covers depression  54  may be used as a speaker box (speaker cavity) for a speaker that is formed from speaker driver  140 . 
       FIG. 44  is a cross-sectional side view of an illustrative configuration for display housing  12  in which each display housing wall has depressions  54 . Depressions  54  may be attached to each other using adhesive  96  (as an example). If desired, one of display housing layers  34  may be formed from a planar metal layer and one of display housing layers  34  may be formed from a fiber composite layer with an array of depressions  54 . The configuration of  FIG. 44  in which both layers  34  have an array of depressions  54  (e.g., in which both of display housing layers  34  are fiber composite layers) is merely illustrative. 
     Foam  36  may fill the gaps formed between display housing walls  34 . Mounting bracket  144  may be formed from a material such as plastic, metal, or fiber composite material. Mounting structures such as illustrative bracket  144  may be separate from layers  34  or may be formed as integral portions of a display housing layer. Connections  146  such as adhesive, welds, solder, or fasteners may be used in attaching mounting bracket structure  144  to display housing layers  34 . Screw  148  may be used to attach mounting bracket  144  and therefore display housing  12  to wall  142  (e.g., by mating with hardware that has already been screwed into wall  142 ). 
       FIG. 45  is a cross-sectional side view of an illustrative configuration for display housing  12  in which display  14  has been mounted so that circuits  122  that have been mounted on printed circuit substrate  120  can be electrically coupled to display  14  through an opening such as opening  150  in one of display housing layers  34 . Components  122  may be mounted in a cavity formed from depression  54 . 
     Display housing layers can be used in forming a stand or other support for device  10 . This type of configuration is shown in  FIG. 46 . In the example of  FIG. 46 , display housing  12  has rear planar metal display housing layer  34 PM and front (inner) fiber composite display housing layer  34 FC. Foam may be interposed between layers  34 PM and  34 FC. Edge member  80  may run along the edges of housing  12 . One of layers  34 PM and  34 FC such as the fiber composite display housing layer  34 FC may extend downwards to form an integral stand such as stand  30 . If desired, part of a stand may be formed in this way. Stand  30  may also be formed from separate structures that are attached to layers  34 PM and  34 FC using fasteners or other attachment mechanisms. 
     Display housing  12  may have three or more display housing layers  34 . In the example of  FIG. 47 , display housing  12  has three display housing layers  34 . The uppermost layer  34 M-A and the lowermost layer  34 M-B (in the orientation of  FIG. 47 ) may be, for example, metal layers. The inner layer  34 FC may be a fiber composite layer with an array of depressions  54 . Adhesive  96  may be used to attach layers  34  together. Display  14  may be mounted on one of the planar metal layers  34 M to facilitate heat dissipation. Components  122  may likewise be mounted on one of the planar metal layers  34 M to help dissipate heat. 
       FIG. 48  is a cross-sectional side view of an edge portion of an illustrative display housing to which a peripheral member  80  such as a metal band, plastic band, or other peripheral wall structure has been attached. As shown in  FIG. 48 , fasteners such as screw (bolt)  150  and nut  152  may be used in attaching peripheral member  80 . In general, any suitable combination of fasteners (rivets, heat stakes, screws, bolts and nuts, etc.), adhesive, interlocking engagement features (e.g., clips and mating holes, etc.), or other fastening mechanisms may be used in attaching peripheral structures to the edge of display housing  12 . The example of  FIG. 48  is merely illustrative. 
       FIG. 49  is a cross-sectional side view of an edge portion of an illustrative display housing in which a peripheral member has been attached to a planar display housing layer (e.g., the lowermost layer  34  in the orientation of  FIG. 49 ) using adhesive  96 . The planar display housing layer may be attached to a display housing layer with depressions using adhesive, fasteners, etc. The display housing layers may be formed from fiber composite material, from metal, from plastic, or other materials. For example, the layer with depressions may be fiber composite or metal or plastic and the planar layer may be fiber composite, metal, or plastic. 
       FIG. 50  is a cross-sectional side view of an edge portion of an illustrative display housing in which a peripheral member has been attached to a display housing layer with an array of depressions (e.g., the lowermost layer  34  in the orientation of  FIG. 50 ) using adhesive  96 . A planar display housing layer and the layer with depressions may be attached to each other with adhesive, fasteners, etc. Display housing layers  34  may be formed from fiber composite material, from metal, from plastic, or other materials. For example, the layer with depressions may be fiber composite or metal or plastic and the planar layer may be fiber composite, metal, or plastic. 
       FIG. 51  is a cross-sectional side view of an illustrative display housing in which a display housing layer with an array of depressions and a display housing layer without depressions have been attached to each other using fasteners such as screw (bolt)  154  and nut  156 . If desired, other fastening techniques may be used to attach display layers  34  together such as combinations of fasteners (rivets, heat stakes, screws, bolts and nuts, etc.), adhesive, interlocking engagement features (e.g., clips and mating holes, etc.), or other fastening mechanisms. The example of  FIG. 51  is merely illustrative. 
     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: 20131023
Publication Date: 20191008
Grant Date: 20191008
Priority Date: 20131023
Inventors: KENNEY, KEVIN M.
RUNDLE, NICHOLAS A.
GARELLI, ADAM T.
MONTPLAISIR, SARAH J.
CROWLEY, MATTHEW W.
MATHEW, DINESH C.
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1601", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04N5/64", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/203", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1601", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/203", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1601", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04N5/64", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 49667554