PATENT DOCUMENT

Publication Number: US-9417661-B2
Application Number: US-201514630434-A
Country: US
Kind Code: B2

Title: Display module

Abstract:
A portable computing device is disclosed. The portable computing device can take many forms such as a laptop computer, a tablet computer, and so on. The portable computing device can include a single piece housing and a display module. The display module can include a protective top glass cover that is bonded to a plastic display frame and surrounded by a seal frame. The display module can also include a display panel and its associated circuitry suspended from the display frame below the protective glass cover. The display module is coupled to the single piece housing using mounting clips in a manner that allows the display module to move relative to the single piece housing during an impact event. The plastic display frame can include inserts that provide structural support near openings in the single piece housing.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a single piece housing with a bottom wall and side walls, wherein the bottom wall and side walls define a front opening of the electronic device; 
 a display module in the front opening that is secured to the single piece housing, wherein the display module comprises: 
 a display frame; 
 a display panel supported by the display frame; 
 a cover supported by the display frame; and 
 a plurality of attachment features that secure the display module to the single piece housing without using a bezel. 
 
     
     
       2. The electronic device defined in  claim 1 , wherein the plurality of attachment features comprises mounting clips. 
     
     
       3. The electronic device defined in  claim 2 , wherein each mounting clip comprises a first portion that is substantially parallel to a surface of the display frame. 
     
     
       4. The electronic device defined in  claim 3 , wherein the first portion of each mounting clip is directly adjacent to the display frame, and wherein each mounting clip is secured to the display frame by a respective fastener. 
     
     
       5. The electronic device defined in  claim 4 , wherein each mounting clip comprises a second portion that protrudes into a respective recess in the single piece housing. 
     
     
       6. The electronic device defined in  claim 1 , further comprising a seal interposed between the side walls and the cover. 
     
     
       7. The electronic device defined in  claim 6 , further comprising an antenna incorporated into the seal. 
     
     
       8. The electronic device defined in  claim 6 , wherein the seal has a portion that extends beneath the cover. 
     
     
       9. An electronic device, comprising:
 a single piece housing with a top opening and a lip portion surrounding the top opening; 
 a cover that is positioned above a display module, wherein the display module is positioned in the top opening and comprises:
 a display panel; 
 display circuitry attached to the display panel; 
 a display panel housing that attaches the display circuitry to the display panel; and 
 a frame that supports the display panel housing, wherein the display panel housing is suspended from the frame. 
 
 
     
     
       10. The electronic device defined in  claim 9 , further comprising at least one mounting clip that secures the frame to the single piece housing. 
     
     
       11. The electronic device in  claim 9 , wherein the electronic device is a tablet computer. 
     
     
       12. The electronic device defined in  claim 9 , further comprising a seal in contact with the lip portion and the cover. 
     
     
       13. The electronic device defined in  claim 12 , wherein the seal has a portion that is interposed between and in contact with the frame and the cover. 
     
     
       14. The electronic device defined in  claim 9 , further comprising a plurality of inserts used to provide additional structural support and reinforcement in portions of the frame. 
     
     
       15. An electronic device, comprising:
 a housing with a bottom wall and side walls, wherein the bottom wall and side walls define a front opening of the electronic device, and wherein the side walls comprise a recess; 
 a display module in the front opening wherein the display module comprises a display frame; 
 a transparent cover layer that is supported by the display frame; 
 a seal interposed between the side walls and the transparent cover layer; and 
 at least one mounting clip having a first portion that is attached to the display frame and a second portion that extends into the recess. 
 
     
     
       16. The electronic device defined in  claim 15 , wherein the seal has a portion that extends underneath the transparent cover layer. 
     
     
       17. The electronic device defined in  claim 16 , wherein the portion is interposed between the transparent cover layer and the display frame. 
     
     
       18. The electronic device defined in  claim 15 , wherein the portion is coupled to the display frame using an adhesive. 
     
     
       19. The electronic device defined in  claim 15 , wherein the display module is configured to move relative to the housing during an impact event. 
     
     
       20. The electronic device defined in  claim 15 , wherein the seal comprises a plastic.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of patent application Ser. No. 13/541,614, filed Jul. 3, 2012, which is a continuation of patent application Ser. No. 12/694,168, filed Jan. 26, 2010, now U.S. Pat. No. 8,238,087, which claims the benefit of provisional patent application No. 61/292,739, filed Jan. 6, 2010, all of which are hereby incorporated by reference herein in their entireties. This application claims the benefit of and claims priority to patent application Ser. No. 13/541,614, filed Jul. 3, 2012, patent application Ser. No. 12/694,168, filed Jan. 26, 2010, now U.S. Pat. No. 8,238,087, issued Aug. 7, 2012, and provisional patent application No. 61/292,739, filed Jan. 6, 2010. 
     This patent application is related to and incorporates by reference in their entirety the following co-pending patent applications:
     (i) U.S. patent application Ser. No. 12/694,085 entitled “HAND HELD COMPUTING DEVICE” by Ternus et al. filed Jan. 26, 2010;   (ii) U.S. patent application Ser. No. 12/694,200 entitled “COMPONENT ASSEMBLY” by McClure et al. filed Jan. 26, 2010;   (iii) U.S. patent application Ser. No. 12/694,162 ) entitled “ASSEMBLY OF DISPLAY MODULE” by McClure et al. filed Jan. 26, 2010; and   (iii) U.S. patent application Ser. No. 12/694,166 entitled “PRINTED CIRCUIT BOARD” by McClure et al. filed Jan. 26, 2010; and   (iv) U.S. patent application Ser. No. 12/694,083 entitled “EDGE BREAK DETAILS AND PROCESSING” by Sweet et. al. filed Jan. 26, 2010 that is, in turn, a continuation in part of and claims priority to U.S. patent application Ser. No. 12/580,934 entitled “METHOD AND APPARATUS FOR POLISHING A CURVED EDGE” by Lancaster et al filed Oct. 16, 2009 that takes priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application Ser. No. 61/249,200 entitled “COMPLEX GEOGRAPHICAL EDGE POLISHING” by Johannessen filed Oct. 6, 2009.   

    
    
     BACKGROUND 
     1. Field of the Described Embodiments 
     The described embodiments relate generally to portable computing devices such as laptop computers, tablet computers, and the like. More particularly, enclosures of portable computing devices and methods of assembling portable computing devices are described. 
     2. Description of the Related Art 
     In recent years, portable computing devices such as laptops, PDAs, media players, cellular phones, etc., have become small, light and powerful. One factor contributing to this reduction in size can be attributed to the manufacturer&#39;s ability to fabricate various components of these devices in smaller and smaller sizes while in most cases increasing the power and or operating speed of such components. The trend of smaller, lighter and powerful presents a continuing design challenge in the design of some components of the portable computing devices. 
     One design challenge associated with the portable computing device is the design of the enclosures used to house the various internal components. This design challenge generally arises from a number conflicting design goals that includes the desirability of making the enclosure lighter and thinner, the desirability of making the enclosure stronger and making the enclosure more esthetically pleasing. The lighter enclosures, which typically use thinner plastic structures and fewer fasteners, tend to be more flexible and therefore they have a greater propensity to buckle and bow when used while the stronger and more rigid enclosures, which typically use thicker plastic structures and more fasteners, tend to be thicker and carry more weight. Unfortunately, however, the increased weight consistent with the more rugged enclosure can lead to user dissatisfaction whereas bowing of enclosures formed of lightweight material can result in damaging some of the internal components (such as printed circuit boards) of the portable device. 
     Furthermore, the enclosures are mechanical assemblies having multiple parts that are screwed, bolted, riveted, or otherwise fastened together at discrete points. These assembly techniques typically complicate the housing design and create aesthetic difficulties because of undesirable cracks, seams, gaps or breaks at the mating surfaces and fasteners located along the surfaces of the housing. For example, a mating line surrounding the entire enclosure is produced when using an upper and lower casing. Moreover, the various components and complicated processes used to manufacture the portable device can make assembly a time consuming and cumbersome process requiring, for example, a highly trained assembly operator working with special tools. 
     Another challenge is related to techniques for mounting structures within the portable computing devices. Conventionally, the structures have been laid over one of the casings (upper or lower) and attached to one of the casings with fasteners such as screws, bolts, rivets, etc. That is, the structures are positioned in a sandwich like manner in layers over the casing and thereafter fastened to the casing. This methodology suffers from the same drawbacks as mentioned above, i.e., assembly is a time consuming and cumbersome process. 
     In view of the foregoing, there is a need for improved component density and associated assembly techniques that reduce cost and improve outgoing quality. In addition, there is a need for improvements in the manner in which handheld devices are assembled such as improvements that enable structures to be quickly and easily installed within the enclosure. It is also desirable to minimize the Z stack height of the assembled components in order to reduce the overall thickness of the portable computing device and thereby improve the overall aesthetic look and feel of the product. 
     SUMMARY OF THE DESCRIBED EMBODIMENTS 
     A portable computing device is disclosed. The portable computing device can include at least a single piece housing having a front opening, the single piece housing further comprising an integral bottom and side walls that cooperate to form a cavity in cooperation with the front opening, an edge of the side walls surrounding and defining the front opening, a display module disposed within the front opening and secured to the seamless housing without a bezel. In the described embodiment, the display module can include at least a display frame, a display panel supported by the display frame, a protective cover supported by the display frame used to protect the display panel, and a plurality of attachment features incorporated into the display frame, wherein the plurality of attachment features secure the display module to the housing when the portable computing device is deemed to be adequately functional. 
     In particular embodiments, the display module can include a protective glass cover bonded to display frame and surrounded by a seal that is coupled to the display frame. The display module can include a touch screen mounted below the protective glass cover. Further, a display panel housing including a display panel and its associated circuitry can be mounted to the display frame such that the display panel is visible through the protective glass cover. 
     In other embodiments, a method is described. The method can be carried out by performing at least the following operations. Electrically connecting a display module configured for use in a portable computing device to at least one operational component located within a cavity formed by a housing of the portable computing device, temporarily securing the display module to a front opening that provides access to the cavity, the temporarily secured display module effectively enclosing the at least one operational component within the housing, functionally testing the portable computing device; and if the portable computing device passes the functional testing, then securing the display module to the housing, otherwise, removing the display panel. 
     A method of assembling a display module to a portable computing device without using a bezel is disclosed. In the described embodiment, the portable computing device has a single piece housing, the single piece housing having a front opening, an integral bottom and side walls that cooperate to form a cavity in cooperation with the front opening, and an edge of the side walls surrounding and defining the front opening. The method can be carried out by performing at least the following: placing the display module within the front opening and secured to the seamless housing, and deploying an attachment feature, the attachment feature being incorporated into the display module. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1A  shows a top view of a portable computing device in accordance with the described embodiments. 
         FIG. 1B  shows a perspective top view of a portable computing device in accordance with the described embodiments. 
         FIG. 2  shows a perspective top view of a display frame and inserts prior to assembly in accordance with the described embodiments. 
         FIG. 3  shows a perspective top view of the display frame assembled with inserts and a seal frame prior to assembly in accordance with the described embodiments. 
         FIG. 4  shows a perspective top view of the display frame assembled with a seal frame in accordance with the described embodiments. 
         FIG. 5  shows a perspective top view of the display frame assembled with a seal, a protective top glass and mounting clips in accordance with the described embodiments. 
         FIG. 6  shows a perspective bottom view of mounting a display panel housing to the protective top glass and frame assembly in accordance with the described embodiments. 
         FIG. 7A  shows a cross sectional view of a portable computing device with the display frame and display panel in an assembled position in accordance with the described embodiments. 
         FIG. 7B  shows a cross sectional view of a portable computing device with a display module in a pre-assembled position in accordance with the described embodiments. 
         FIG. 8  shows side views of a mounting mechanism in accordance with the described embodiments. 
         FIG. 9  shows a side view of a fixture assembly in accordance with the described embodiments. 
         FIG. 10  is a flow chart of a method for assembling a display frame including securing a protective glass layer to the display frame. 
         FIG. 11  is a flow chart of a method for integrating a display module into a portable computing device. 
     
    
    
     DESCRIBED EMBODIMENTS 
     In the following paper, numerous specific details are set forth to provide a thorough understanding of the concepts underlying the described embodiments. It will be apparent, however, to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the underlying concepts. 
     This paper discusses an aesthetically pleasing portable computing device that is easy to carry with one hand and operate with the other. The portable computing device can be formed of a single piece seamless housing and an aesthetically pleasing protective top layer that can be formed of any of a number of durable and strong yet transparent materials such as highly polished glass or plastic. For the remainder of this discussion, however, the protective top layer can take the form of highly polished cover glass without any loss in generality. Furthermore, the uniformity of the appearance of the portable computing device can be enhanced since (unlike conventional portable computing devices) the cover glass can be mounted to the single piece seamless housing without the use of a bezel. This simplicity of design can accrue many advantages to the portable computing device besides those related to aesthetic look and feel. For example, fewer components and less time and effort can be required for assembly of the portable computing device, and the absence of seams in the single piece housing can provide good protection against environmental contamination of internal components. Moreover, the ability of the portable computing device to successfully withstand applied loads (such as from day to day use) as well as those from less frequent but potentially more damaging events such as being dropped can be substantially improved over conventional portable computing devices. 
     In the described embodiments, the single piece seamless housing can be formed from plastic or metal. In the case where the single piece seamless housing is formed of metal, the metal can take the form of a single sheet (such as aluminum). The single sheet of metal can be formed into a shape appropriate for housing various internal components as well as providing various openings into which switches, connectors, displays, and so on can be accommodated. The single piece seamless housing can be forged, molded, or otherwise processed into a desired shape. The shape of the housing can be asymmetric in that an upper portion of the housing can be formed to have a substantially different shape than that exhibited by a lower portion of the housing. For example, the upper portion of the housing can have surfaces that meet at distinct angles forming well defined boundary whereas the lower portion can be formed to have a surface with a spline shape. The transition zone between the upper portion having distinct edges and the lower, spline shaped portion can take the form of an edge having a rounded shape providing both a natural change from the upper portion of the housing (i.e., the area of distinct edges) and the smoother surface presented by the lower portion of the housing. It should also be noted that in addition to providing a more aesthetically pleasing transition, the rounded shape of the edge in the transition zone can provide a more comfortable feel when being held in a user&#39;s hand either during use or merely being carried about. One of the advantages to using metal for the housing is ability of metal to provide good electrical grounding for any internal components requiring a good ground plane. For example, performance of a built in RF antenna can be substantially improved when a good ground plane is provided. Moreover, a good ground plane can be used to help mitigate the deleterious effects caused by, for example, of electromagnetic interference (EMI) and/or electrostatic discharge (ESD). 
     It should be noted that throughout the following discussion, the term “CNC” is used. The abbreviation CNC stands for computer numerical control and refers specifically to a computer controller that reads computer instructions and drives a machine tool (a powered mechanical device typically used to fabricate components by the selective removal of material). It should be noted however, that any appropriate machining operation can be used to implement the described embodiments and is not strictly limited to those practices associated with CNC. 
     These and other embodiments are discussed below with reference to  FIGS. 1-10 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. In particular, with respect to  FIGS. 1A and 1B , a portable computing device is described. In  FIGS. 2-6 , various stages of assembling display components associated with the portable computing device are described. In  FIGS. 7A-7B , securing assembled display components to a portable computing device housing are discussed. In  FIG. 8 , an alternate coupling mechanism for securing the assembled display components to the portable computing device housing are discussed. In  FIGS. 9 and 10 , a fixture assembly and a method of using the fixture assembly to secure a protective top glass to a display frame and seal assembly are described. In  FIG. 11 , a method of assembling a portable computing device is described. 
       FIG. 1A  illustrates a specific embodiment of portable computing device  100 . More specifically,  FIG. 1A  shows a full top view of fully assembled portable computing device  100 . Portable computing device  100  can process data and more particularly media data such as audio, video, images, etc. By way of example, portable computing device  100  can generally correspond to a device that can perform as a music player, game player, video player, personal digital assistant (PDA), tablet computer and/or the like. With regards to being handheld, portable computing device  100  can be held in one hand by a user while being operated by the user&#39;s other hand (i.e., no reference surface such as a desktop is needed). For example, the user can hold portable computing device  100  in one hand and operate portable computing device  100  with the other hand by, for example, operating a volume switch, a hold switch, or by providing inputs to a touch sensitive surface such as a display or pad. 
     Portable computing device  100  can include single piece seamless housing  102  that can be formed of any number of materials such as plastic or metal which can be forged, molded, or otherwise processed into a desired shape. In those cases where portable computing device  100  has a metal housing and incorporates RF based functionality, it may be advantageous to provide at least a portion of housing  102  in the form of radio (or RF) transparent materials such as ceramic, or plastic. In any case, housing  102  can be configured to at least partially enclose any suitable number of internal components associated with the portable computing device  100 . For example, housing  102  can enclose and support internally various structural and electrical components (including integrated circuit chips and other circuitry) to provide computing operations for portable computing device. The integrated circuits can take the form of chips, chip sets, modules any of which can be surface mounted to a printed circuit board, or PCB, or other support structure. For example, a main logic board (MLB) can have integrated circuits mounted thereon that can include at least a microprocessor, semi-conductor (such as FLASH) memory, various support circuits and so on. 
     Housing  102  can include opening  104  for placing internal components and may be sized to accommodate a display assembly or system suitable for providing a user with at least visual content as for example via a display. In some cases, the display system can include touch sensitive capabilities providing the user with the ability to provide tactile inputs to portable computing device  100  using touch inputs. The display system can be formed of a number of layers including a topmost layer being a transparent protective layer  106  formed of polycarbonate or other appropriate plastic or highly polished glass. Using highly polished glass, protective layer  106  can take the form of cover glass  106  substantially filling opening  104 . Seal  108  can be used to form a gasket between cover glass  106  and housing  102 . Seal  108  can be formed of a resilient material such as a plastic along the lines of thermoplastic urethane or TPU. In this way, seal  108  can provide protection against environmental contaminants from entering the interior of portable computing device  100 . Racetrack  110  can be defined as the uppermost portion of the housing  102  that surrounds cover glass layer  106 . In order to maintain the desired aesthetic look and feel of portable computing device  100 , it is desirable that any offsets between the housing  102  and cover glass  106  be minimized by centering racetrack  110 . 
     Although not shown, the display panel underlying cover glass  106  can be used to display images using any suitable display technology, such as LCD, LED, OLED, electronic or e-inks, and so on. Display assembly may be placed and secured within the cavity using a variety of mechanisms. In one embodiment, the display system is snapped into the cavity. It may be placed flush with the adjacent portion of the housing. In this way, the display can present visual content that can include video, still images, as well as icons such as graphical user interface (GUI) that can provide information the user (e.g., text, objects, graphics) as well as receive user provided inputs. In some cases, displayed icons can be moved by a user to a more convenient location on the display. For example, GUI can be moved by the user manually dragging GUI from one location to a more convenient location. The display can also provide a user with tactile feedback provided by a number of haptic actuators usually, but not always, arranged in an array of haptic actuators incorporated into the display. In this way, the haptic actuators can provide the user with tactile feedback. 
     In some embodiments, a display mask (not shown) can be applied to, or incorporated within, or under cover glass  106 . The display mask can be used to accent an unmasked portion of the display used to present visual content. The display mask can be used to make less obvious home button  112  used to provide a specific input such as change display mode, for example to portable computing device  100 . The display mask can render home button  112  less obvious by, for example, being closer in tone or color to home button  112 . For example, if home button  112  is formed of a material that is somewhat darker (such as gray or black) than cover glass  106 , then using a similarly colored display mask can reduce the visual impact of home button  112  when compared with the unmasked portion of cover glass  106 . In this way, the visual impact of home button  112  can be reduced by being integrated into the overall look of the display mask. Furthermore, the display mask can provide a natural mechanism for directing the attention of a viewer to the unmasked area of the display used to present visual content. 
     Portable computing device  100  can include a number of mechanical controls for controlling or otherwise modifying certain functions of portable computing device  100 . For example, power switch  114  can be used to manually power on or power off portable computing device  100 . Mute button  116  can be used to mute any audio output provided by portable computing device  100  whereas volume switch  118  can be used to increase/decrease volume of the audio output by portable computing device  100 . It should be noted that each of the above described input mechanisms are typically disposed through an opening in housing  102  such that they can couple to internal components. In some embodiments, portable computing device  100  can include a camera module configured to provide still or video images. The placement may be widely varied and may include one or more locations including for example front and back of the device, i.e., one through the back housing, the other through the display window. 
     Portable computing device  100  can include a mechanism for wireless communications, as either a transceiver type device or receiver only, such as a radio, portable computing device  100  can include an antenna that can be disposed internal to a radio transparent portion of housing  102 . In some embodiments, an antenna can be incorporated into seal  108  or cover glass  106 . In other embodiments, a portion of housing  102  can be replaced with radio transparent material in the form of an antenna window described in more detail below. The radio transparent material can include, for example, plastic, ceramic, and so on. The wireless communications can be based on many different wireless protocols including for example 3G, 2G, Bluetooth, RF, 802.11, FM, AM, and so on. Any number of antennas may be used, which can use a single window or multiple windows depending on the needs of the system. In one embodiment, the system can include at least first and second antenna windows built into the housing (upper and logo). 
       FIG. 1B  shows a perspective top view of portable computing device  100  in accordance with the described embodiments. As shown in  FIG. 1B , portable computing device  100  can include one or more speakers  120  used to output audible sound. Portable computing device  100  can also include one or more connectors for transferring data and/or power to and from portable computing device  100 . For example, portable computing device  100  can include multiple data ports, one for each configuration of portrait mode and landscape mode. However, the currently described embodiment includes single data port  122  that can be formed of connector assembly  124  accommodated within an opening formed along a first side of housing  102 . In this way, portable computing device  100  can use data port  122  to communicate with external devices when portable computing device  100  is mounted in docking station. It should be noted that in some cases, portable computing device  100  can include an orientation sensor or an accelerometer that can sense the orientation or movement of portable computing device  100 . The sensor can then provide an appropriate signal which will then cause portable computing device  100  to present visual content in an appropriate orientation. 
     Connector assembly  124  can be any size deemed appropriate such as, for example, a 30 pin connector. In some cases, the connector assembly  124  can serve as both a data and power port thus obviating the need for a separate power connector. Connector assembly  124  can be widely varied. In one embodiment, connector assembly  124  can take the form of a peripheral bus connector, such as a USB or FIREWIRE connector. These types of connectors include both power and data functionality, thereby allowing both power delivery and data communications to occur between the portable computing device  100  and the host device when the portable computing device  100  is connected to the host device. In some cases, the host device can provide power to the media portable computing device  100  that can be used to operate the portable computing device  100  and/or charge a battery included therein concurrently with the operating. 
       FIG. 2  shows a perspective top view of a display frame  200  and inserts,  202 ,  204 ,  206 ,  208  and  210  prior to assembly. The display frame  200  can be formed from a material, such as a plastic or a metal. For instance, the display frame can be formed using thermoplastic urethane or TPU. The inserts can be used to provide additional structural support and reinforcement in regions where the display frame is proximate to openings in the housing  102  (see  FIGS. 1A and 1B ). For example, insert  202  is proximate to an opening for a mechanism switching power on or off, insert  204  is proximate to an opening for a mechanism that enables a muting function to be activated and a mechanism that enables volume control, insert  206  is proximate to an opening for multi-pin connector and insert  210  is proximate to an opening for an audio output interface, a microphone and a boot switch. 
     In particular embodiments, insert  208  can be eliminated. When insert  208  is included, it can provide structural support for an opening. The opening can be associated with a number of different functions. For instance, the opening can be used to provide audio output from an internal speaker, to insert or remove a Sim card, to provide external access to an external power and/or data pin connector, to provide support for a docking interface and to provide access to additional actuator, such as a switch or a button. 
     In general, the number, placement location and size of the inserts can be varied and is not limited to the example of  FIG. 2 . For example, in one embodiment, as described above, the opening and its associated insert  208  can be eliminated. In other embodiments, the opening for the muting and volume control mechanisms can be moved away from the corner resulting in changes to the display frame  200  and a change in a location of insert  204  to accommodate the different location of the opening. In another example, a size of insert  206  can be increased to accommodate multiple connectors, such as a separate power and data connectors. 
     The inserts can be formed into an appropriate shape from a rigid material, such as a metal (e.g., stainless steel or magnesium). In one embodiment, the inserts can be formed from a polymer, such as IXEF™ manufactured by Solvay Advanced Polymers, LLC. As is shown in  FIG. 3 , the inserts can be incorporated into the display frame  200 . In one embodiment, the inserts can be mechanically snapped into place. In another embodiment, an adhesive, such as an epoxy can be used to attach the inserts to the display frame. 
     In yet another embodiment, the inserts can be loaded into a plastic molding tool to form an integrated assembly, such as a plastic/metal assembly when metal inserts are used with a plastic display frame  200 . After forming the display frame  200  and inserts, the inserts can incorporated into the display frame  200  and the combined assembly can be loaded into an over mold tool. The over mold tool can be used to apply an additional layer of plastic that bonds the inserts to the display frame  200 . When the inserts are integrated into the display frame in this manner, a number of apertures can be designed into the inserts to improve adhesion between the insert material and the display frame material when additional plastic is added. 
       FIG. 3  shows a perspective top view of the display frame  200  assembled with inserts and a seal frame  108  prior to assembly in accordance with the described embodiments.  FIG. 4  shows a perspective top view of the display frame  200  assembled with a seal frame  108  in accordance with the described embodiments. In one embodiment, the seal  108 , when coupled to the display frame  200  (see  FIG. 4 ), can rest on a ledge  205   b  around an outer perimeter of the display frame. The seal  108  can include a ledge  205   a , around its perimeter, that rests on ledge  205   b  when the two components are seated against one another. 
     In particular embodiments, the seal can include gaps, such as  201 , that allow a component, such as a mounting tab (see  FIGS. 5 and 6 ), secured to the display frame  200 , to extend from the display frame  200 . The seal  108  can also include gaps associated with openings in the housing  102  (e.g., see description of inserts with respect to  FIGS. 2 and 3 ). The seal  108  can have parts, such as  203 , that include posts and ledges that hang below a top surface of the seal. The posts can be aligned with indentations in the display  200  to form a conformal fit and prevent the seal from sliding relative to the display frame  200 . When the seal  108  is coupled to the display frame  200  (see  FIG. 4 ), the parts, such as  203 , can extend underneath the display frame  200  (see  FIG. 7  for a cross-sectional view). For example, portions of seal  108  can be located beneath ledge  205   b  on the display frame  200 . In particular embodiments, the seal  108  can be coupled to the display frame using an adhesive, such as an epoxy, using a fastener, such as a screw, or combinations thereof 
     In  FIG. 4 , the seal  108 , display frame  200  and inserts are shown assembled. A protective top glass layer can be placed on top of the assembly.  FIG. 5  shows a perspective top view of the display frame  200  assembled with a seal  108 , a protective top glass  106  and mounting clips  212  in accordance with the described embodiments. The top glass  106  is mounted to the display frame  200 , inserts and seal  108  as shown in  FIG. 4 . A method of mounting the top glass  106  to the display frame  200  is described with respect to  FIGS. 9 and 10 . The top glass  106  includes and aperture  214  for button  112  (see  FIGS. 1A and 1B ). 
     Mounting clips  212  are attached to the display frame  200 . In one embodiment, the mounting clips  212  are coupled to the display frame  200  using a fastener, such as a screw. The mounting clips  212  can be used to secure the display components shown in  FIG. 5  within housing  102 . Details of the display components relative to the housing  102  and mounting clips  212  are described with respect to  FIG. 7A . 
       FIG. 6  shows a perspective bottom view of mounting a display panel housing  220  to the protective top glass and frame assembly in accordance with the described embodiments. As is shown in  FIG. 7 , the display panel housing  220  can support and secure a display panel  224  and associated display circuitry  226 . A touch screen  222  can be mounted below the protective top glass  106 . As previously described, the mounting clips  212  can be secured to the display frame  200  via a fastener, such as  216 . 
     As described in more detail with respect to  FIG. 7A , when assembled, the display panel housing  220  hangs below display frame  200 . The display panel housing  220  includes a number of mounting tabs with an aperture, such as  219 . Fasteners  218  can be threaded through the apertures in the mounting tab and secured to corresponding mounting ports in the display frame  200 . In one embodiment, the display panel  224  within the housing  220  can be attached to a bottom portion of touch screen  222  using an appropriate fixing agent, such as an epoxy or an adhesive tape. The display panel  224  can also be sealed to the back of the protective layer using a gasket, such as  223 , that can be adhered to the display using an adhesive material. 
     In an impact invent, such as dropping the portable computing device, impact stresses can be distributed through out the portable computing device. During the impact invent, the stress loads experienced by each component can depend on the direction of the impact and how each component is coupled to one another. For example, the mounting tabs  219  couple to the display panel housing  220 , display panel  224  and associated circuitry to the display frame  200 . Depending on a number of mounting tabs that are used, the coupling between the display panel housing and display frame can be tighter or looser. Typically, the tighter the coupling between the two components, the more the two components tend to move as a single unit. Tighter coupling can be accomplished by using more mounting tabs, such as  219 , between the display panel housing  220  and looser coupling can be accomplished by using relatively less mounting tabs. 
     In impact events, it was found that providing the display panel  224  with a greater capability for flexure reduced the likelihood of a stress crack forming in the display panel  224 . In one embodiment, the display panel housing  220  is only coupled to the display frame  200  at the ends to provide more flexure. The display panel housing  220  is proximately rectangular and the mounting tabs are located on the shorter sides providing the greatest distance between mounting tabs on the two sides in which they are placed. Thus, during an impact invent, flexing can occur over a greater length and the stresses can be more spread out. 
     Also, it was found that placing the mounting tabs  219  in lower stress areas tended to reduce the likelihood of a stress crack forming in the panel during an impact event. A stress distribution for the display panel housing  220  and its associated components can be predicted for different impact invents to determine optimum locations to place the mounting tabs. In another embodiment, the mounting tabs, such as  219 , can be located in areas that are predicted to have lower stresses than other areas, such that less stress is transferred to the display panel housing  220  from the display frame  200 . Further, a total number of mounting tabs can be reduced to decrease the coupling between the display frame  200  and the display panel housing  220 . For instance, no mounting tabs are found on two of the sides of the display panel housing  220  and a number mounting tabs on the other sides can be reduced, such as the three mounting tabs  219  shown on each side in  FIG. 6 . 
       FIG. 7A  shows a cross sectional view of a portable computing device with a display module  225  including the display frame  200  and display panel  224  in an assembled position within the housing  102 . The display module  225  is assembled from the components shown in  FIG. 6 . The display panel housing  220  includes a frame or one or more brackets that secure the display panel  224  and the display circuitry  226 . The seal  108  on the display frame is in contact with a lip  228  of the housing  102 . In an assembled position, when the device  100  is facing upwards, i.e., the protective top glass  106  is facing upwards, the display panel housing  220  and its associated display components are suspended or hang down from the display frame  200 . 
     To install the display module  225  into the housing  102 . The mounting clips  212  which are distributed around the perimeter of the display frame  200  (e.g., see  FIGS. 5 and 6 ) are compressed towards the display frame  200  allowing the mounting tabs  212  to move past the lip of the housing  220 . Once a tip of the mounting clip  212  clears the lip  228 , the mounting tab can expand outward underneath the lip  228  and into a notch  227  in the display housing  102 . In the expanded position, the mounting clips, such as  212 , can prevent the display frame  200  and its associated components from being removed from the housing  102 . More details of installing the display module  225  into the housing are described with respect to  FIG. 7B . 
     In particular embodiment, the notch can be formed by removing a rectangular portion of housing  102 . The width of the notch can be wider than the width of clip  212  to accommodate the clip  212 . A number of the notches can be formed around the perimeter of housing  220  to accommodate each of the clips  212 . The number of clips can be varied and hence the number of notches formed in the housing can be varied between designs. 
     Compressive forces, such as  229 , can be used to keep the protective top glass, flush with the top of housing. These forces can be applied to the display frame  200  or other components coupled to the display frame  200 , such as the display panel housing  220 . The forces, such as  229 , can be applied at a number of locations throughout the device  100  and are not limited to the location indicated by  229 . As an example, in some locations, the display frame  200  or its associated components can be in contact with foam or another material, such as a high-strength foam, that is in compression. The material can be placed in compression when the display frame  200  is inserted into the housing  102 . 
     The compressed material can apply a compressive force upwards to the display frame  200 . The compressive force can cause the mounting clips, such as  212 , to move or spread outwards, i.e., towards the housing  102 . In another embodiment, one or more springs (not shown) can be used to provide a compressive force directly to the display frame  200  or the forces can be provided through one or more intermediary components linked to the display frame  200 . For instance, a spring can be located under a component that is under the display frame  200 . The spring can be oriented to press upwards against the component and towards the display frame  200 . The component can be in contact with display frame  200  to transfer a compressive force from the spring to the display frame  200  via the component. 
     During a drop event, the seal  108  and/or the mounting clips, such as  212 , can allow some lateral movement and provide some force dampening. For instance, when a force is applied in the direction  231 , the seal  108  and possibly one or more of the mounting clips, such as  212  can be compressed absorbing a portion of the force. One or more of the mounting clips on a side opposite (not shown) can expand or stretch outward, i.e., lengthen. The expansion of the mounting clips outward on the opposite side can keep the display assembly in place. After the seal  108  and/or mounting clip  212  uncompress, the display frame can move in the opposite direction of force  231 . This type of interaction involving a compression and subsequent expansion of the seal  108  and movements of the mounting clip can occur for any resultant forces that are parallel to top surface of the protective glass  106 , such as a resultant force in the opposite direction of  231  or a resultant force perpendicular to  231  (i.e., into the page). 
       FIG. 7B  shows a cross sectional view of a portable computing device  100  with a display module  225  in a pre-assembled position in accordance with the described embodiments. During installation of the display module  225  to the housing  102  shims, such as  241 , can be inserted between the housing  102  and the mounting clips. The shims, such as  241 , hold the mounting clip in a compressed position  212   a . In one embodiment, a number of shims can be used, such as one shim for each clip. In other embodiments, a single shim can be used for multiple mounting clips. For example, a single shim can be used to compress all of the mounting clips on a side of the display module  225 . In yet another embodiment, a shim tool that follows the inner perimeter of housing  102  near the lip  228  can be used to compress all of the shims at one time. The shim tool can be removed as a single piece to allow the mounting clips to engage. 
     The display module  225  can be connected to the electrical components within the portable device and the display module  225  can be tested prior to removing the shims, such as  241 , that allow the mounting clips, such as  212   a  to engage. Besides the display module  225 , other electrical internal electrical components such as a main logic board can be also tested since one the display module  225  is installed direct access to many of the internal components is no longer possible. Once it is determined that display module and/or electrical components are operating acceptably, the shims can be removed. A testing method is described in further detail with respect to  FIG. 11 . 
     After the shims are removed and mounting clips expand into place, the display module  225  and other internal components can be re-tested. If it is determined that there is a malfunction, it may be necessary to remove the display module  225  from the housing  102 . An upward force can be applied pull the display module  225  away from the housing. In one embodiment, the upward force can be applied using a device, such as a suction cup  243 . 
     In a particular embodiment, the upward force on the display module can be applied until one or more of the mounting clips break. For example, the upward force can be applied on one corner of the display module and then the mounting clips can be broken in a zipper like fashion, i.e., one at a time. When enough of the mounting clips are broken (it may not be necessary to break all of the mounting clips to remove the display module  225 ), the display module  225  can removed from the housing. After the display module  225  is removed, broken clip portions can be removed from the interior of the housing  102  and needed repairs can be determined. If the display module  225  is functioning properly, new mounting clips can be installed in the display module  225  and the display module  225  can be reinstalled. In some embodiments, it may be possible to remove the display module  225  without breaking the mounting clips. One such example is described as follows with respect to  FIG. 8 . 
       FIG. 8  shows side views of a mounting mechanism  232  in accordance with the described embodiments. The mounting mechanism  232  includes three track portions, such as  231  in contact with and configured to move along a track  234 . Two bump portions, such as  210 , are located between the three track portions. The mounting mechanism can be a sheet, such as a metal sheet with some width and some thickness. The sheet can be bent or shaped to form  232  or some shape proximate to the  232 . The mounting mechanism is shown in an unloaded configuration,  230   a  and a loaded configuration,  230   b.    
     The mounting mechanism can be configured such that when a force, such as  236 , is applied and the mounting mechanism is loaded, the bump portions flatten and the mounting mechanism lengthens. The lengthening of the mounting mechanism causes the end track portions to move outwards and slide along track  234 . After the mounting mechanism  232  is unloaded, it can be designed to return to its unloaded configuration,  230   a , where the height of the bumps increases and the end track portions move inward to allow the mounting mechanism to shorten. 
     In one embodiment, the mounting mechanism  232  can be used as alternate to the mounting clips, such as  212 , or can be used in conjunction with the mounting clips, such as  212  (see  FIGS. 7A and 7B ). The mounting mechanism  232  can be located on a side of the display frame  200  like mounting clip,  212 . Referring to  FIG. 7B , in an unloaded position, prior to installing the display module  225 , the mounting mechanism  232  can stick out past the housing lip  228 . A load can be applied to the mounting mechanism  232  to flatten it and allow the display module  225  to slide past the lip  228 . 
     After the lip  228  is cleared, the load can be removed from the mounting mechanism. The mounting mechanism  232  can then expand to lock the display module  225  into place. For instance, the mounting mechanism  232  could sit in notch  227  when expanded. The notch  227 , in this example, can also be a slot to accommodate both bumps of the mounting mechanism  232  rather than forming separate notches for each bump. 
     The display module  225  can be removed after it has been installed in housing  102 . Using mounting mechanisms, such as  232 , the display module  225  can be removed by inserting a thin strip, such as a thin metal blade, between the seal  108  and the lip  228 . The thin strip can be inserted between the bumps of the mounting mechanism  232 . The thin strip can be slid over to one side or the other to load and flatten one of the bumps of the mounting mechanism, which flattens the other bump. When the mounting mechanism is flattened, it may be possible to lift the display module  225  such that the mounting mechanism slides by the lip  228  of the housing allowing the display frame to be removed without breaking the mounting mechanism  232 . 
     As previously described with respect to  FIG. 7B , using clips  212 , the display module  225  can be removed by lifting the display frame and breaking mounting clips, such as  212 . For instance, suction cups can be applied to the top of protective glass  106  to lift out the display module  225 . To re-install the display module  225 , new mounting clips can be attached. One advantage of mounting mechanism  232  is that it may be possible to remove the display module  225  without breaking mounting mechanism  232 . 
       FIG. 9  shows a side view of a fixture assembly  244 . With respect to  FIG. 9 , a method of assembly is described that can be used to provide an even spacing around the perimeter of the protective top glass  106  between the protective top glass  106  and seal  108 . The fixture  244  can be used to secure the display frame  200  such that a surface that supports the protective top glass  106  is in a horizontal position. In one embodiment, the protective top glass can be seated on a portion of the seal  108  and a portion of the frame  200  as is shown. 
     An adhesive, such as  238 , can be applied to the display frame  200 . For instance, a line of liquid epoxy can be applied around the display frame  200  as an adhesive. Next, a shim ring  240  can be placed in contact with an inner surface perimeter of the seal  108  (The shim ring is configured to conform to the inner perimeter of the seal  108 , which is proximately rectangular.) Then, the protective top glass layer can be placed between the shim ring and in contact with the adhesive  238 . 
     A weight, such as  242  can be placed on top of the protective glass layer  106 . In one embodiment, the weight can be held in place by the shim ring  240 . The weight  242  can be used to keep the protective top glass  106  horizontal while the adhesive is curing. Finally, in one embodiment, the fixture  244  and its content can be placed in an oven to aid in curing of the adhesive  238 . In one embodiment, a curing time can be about ½ hour. 
       FIG. 10  is a flow chart of a method  300  for assembling a display frame, such as  200 , including securing a protective glass layer, such  106 , to the display frame. In  302 , a display frame including a seal as described with respect to  FIG. 4  can be provided. Providing the display frame can involve forming a plastic display frame and inserts for structural reinforcement, loading the inserts into the display frame, adding a plastic layer over the inserts to bond the inserts to the display frame and bonding the seal  108  to the display frame including the inserts, as was previously described. In  304 , a display frame and seal can be loaded into a fixture assembly as described with respect to  FIG. 9 . In  306 , an adhesive can be applied to the display frame secured in the fixture assembly. 
     In  308 , a shim ring can be placed proximate to an inner edge of the seal on the display frame  200 . In  310 , the protective glass can be placed within the shim ring and in contact with the adhesive. In  312 , a weight can be placed over the protective glass. In  314 , the fixture assembly with the display frame can be placed in a curing device, such as an oven. In  316 , the fixture assembly and the associated components can be placed in the curing device for some time period to allow the bond between the protective top glass and the adhesive to form. Then, the fixture assembly can be removed from the oven, the weight and the shim ring can be removed and the display frame with the bonded protective top glass can be removed from the fixture assembly. 
       FIG. 11  is a flow chart of a method  400  for integrating a display module into a portable computing device. In  402 , the display module can be electrically connected to at least one operational component of the portable computing device. In  404 , the display module can be temporarily secured to the portable device housing (see  FIG. 7B ). In  406 , the portable computing device can be functionally tested. In  410 , a determination can be made in regards to whether the device has passed a testing regimen. When the device passes the testing regimen, in  412 , the display module can be secured to the housing (see  FIG. 7A ). 
     When the device does not pass the test regimen, in  414 , the display module can be disconnected and removed from the housing. Since the mounting clips have not been engaged yet, the display module can be removed without breaking the mounting clips. In  416 , necessary repairs for the portable device can be determined and components can be replaced as needed. Then, the method can be repeated starting with  402 . 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, DVDs, magnetic tape, optical data storage devices, and carrier waves. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. Thus, the foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings. 
     The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents. 
     While the embodiments have been described in terms of several particular embodiments, there are alterations, permutations, and equivalents, which fall within the scope of these general concepts. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present embodiments. For example, although an extrusion process is preferred method of manufacturing the integral tube, it should be noted that this is not a limitation and that other manufacturing methods can be used (e.g., injection molding). It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the described embodiments.

Metadata:
Filing Date: 20150224
Publication Date: 20160816
Grant Date: 20160816
Priority Date: 20100106
Inventors: MCCLURE STEPHEN R.
BANKO JOSHUA D.
TERNUS JONATHAN
MORRIS MATTHEW B.
THOMPSON PETER M.
GIBBS KEVIN
VAN VORHIS TIMOTHY G.
ADAMCYK MARTIN B.
LUCCHESI ARTHUR J.
CARPENTER BRIAN SCOTT
Assignee: APPLE INC
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Family ID: 43064392