PATENT DOCUMENT

Publication Number: US-9766662-B2
Application Number: US-201514693814-A
Country: US
Kind Code: B2

Title: Conductive gasket for a portable computing device

Abstract:
A shield feature and method of forming to prevent transmission of electromagnetic radiation is disclosed. The shield feature may include a first protrusion and a second protrusion, both of which are formed from an electrically conductive material. A non-electrically conductive material may cover the electrically conductive material in certain regions. The first protrusion, the second protrusion, and an extension between the first protrusion and the second protrusion are free of non-electrically conductive material, allowing the electrically conductive material to engage an enclosure of an electronic device. Also, a distance separates the first protrusion and the second protrusion that is less than a distance defined by a wavelength of the electromagnetic radiation, allowing the shield feature to prevent the electromagnetic radiation from passing through the shield feature. Also, the shield feature may further form an electrical grounding path for an internal component to electrically ground the internal component with the enclosure.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 an electrically conductive enclosure that includes a top case and a bottom case; 
 an antenna; and 
 a shield feature that shields the antenna from electromagnetic radiation generated by an internal component of the electronic device, the shield feature formed from an electrically conductive material and comprising:
 a base portion, 
 a first protrusion extending from the base portion, and 
 a second protrusion extending from the base portion and separated from the first protrusion by a gap that is less than a characteristic wavelength of the electromagnetic radiation, wherein the first protrusion and the second protrusion are formed at a first angle with respect to the base portion, and wherein the top case combines with the bottom case to engage and compress the first protrusion and the second protrusion to a second angle less than the first angle. 
 
 
     
     
       2. The electronic device of  claim 1 , further comprising a non-electrically conductive material surrounding a portion of the electrically conductive material. 
     
     
       3. The electronic device of  claim 1 , wherein the first protrusion includes a first tip region formed from the electrically conductive material, and wherein the second protrusion includes a second tip region formed from the electrically conductive material. 
     
     
       4. The electronic device of  claim 1 , wherein the
 top case includes a recessed region, and 
 wherein the shield feature is disposed at least partially within the recessed region. 
 
     
     
       5. The electronic device of  claim 1 , wherein:
 the first protrusion includes a first hollow region, 
 the second protrusion includes a second hollow region, and 
 the first hollow region and the second hollow region allow the first protrusion and the second protrusion, respectively, to reduce to the second angle. 
 
     
     
       6. The electronic device of  claim 1 , further comprising a cover, wherein the antenna is disposed the cover to hide the antenna. 
     
     
       7. The electronic device of  claim 1 , wherein the first protrusion and the second protrusion are configured to bend and at least partially disengage with the bottom case. 
     
     
       8. A shield feature for preventing transmission of electromagnetic radiation, the shield feature comprising:
 a first layer comprising an electrically conductive material, the first layer including:
 a first protrusion that includes a first tip region, and 
 a second protrusion that includes a second tip region, wherein the second protrusion is separated from the first protrusion by a distance less than a wavelength of the electromagnetic radiation; and 
 a second layer covering the first protrusion except for the first tip region, the second layer further covering the second protrusion except for the second tip region. 
 
 
     
     
       9. The shield feature of  claim 8 , wherein the second layer comprises a non-electrically conductive layer. 
     
     
       10. The shield feature of  claim 9 , wherein the first protrusion comprises a conical shape and a hollow region that defines a first angle of the conical shape, and wherein the first tip region receives a force causing the conical shape to reduce from the first angle to a second angle less than the first angle. 
     
     
       11. The shield feature of  claim 10 , wherein the first layer includes an electrically conductive silicone, and wherein the second layer includes a non-electrically conductive silicone. 
     
     
       12. The shield feature of  claim 11 , further comprising an adhesive layer, wherein the first layer includes a first extension and a second extension, and wherein the first extension and the second extension extend beyond the adhesive layer to engage an enclosure of an electronic device. 
     
     
       13. The shield feature of  claim 8 , wherein the first tip region, the second tip region, and a portion of the first layer extend beyond the second layer to engage an enclosure of an electronic device. 
     
     
       14. The shield feature of  claim 8 , wherein the first layer includes a base portion that surrounds the first protrusion and the second protrusion. 
     
     
       15. A method for forming a shield feature suitable for preventing electromagnetic radiation, the method comprising:
 forming a first protrusion having a first tip region and a second protrusion having a second tip region from a first layer that includes an electrically conductive material, the second protrusion separated from the first protrusion by a distance less than a wavelength of the electromagnetic radiation; and 
 applying a second layer to the first protrusion and the second protrusion, the second layer including a non-electrically conductive material that covers (i) the first protrusion except for the first tip region and (ii) the second protrusion except for the second tip region. 
 
     
     
       16. The method of  claim 15 , further comprising securing an adhesive layer with at least the first layer. 
     
     
       17. The method of  claim 15 , further comprising laser ablating the second layer in a location below the first tip region and the second tip region. 
     
     
       18. The method of  claim 15 , wherein forming the first protrusion and the second protrusion comprises separating the first protrusion from the second protrusion by a distance less than a wavelength of the electromagnetic radiation. 
     
     
       19. The method of  claim 15 , wherein forming the first protrusion comprises forming a protrusion having a conical shape and a hollow region.

Description:
FIELD 
     The described embodiments relate generally to an electronic device. In particular, the present embodiments relate to an electromagnetic shielding feature to shield internal components within the electronic device from emanating electromagnetic radiation thereby reducing or prevent unwanted electromagnetic interference. 
     BACKGROUND 
     Electronic devices are known to include wireless communication devices to establish wireless communication via electromagnetic radiation with external devices. For example, a portable computing device (such as a laptop) can include wireless communication devices such as a WiFi radio circuit used to establish a wireless Internet communication and/or a Bluetooth radio circuit used to establish a wireless communication with an accessory (such as a mouse). The wireless communication devices may include an antenna to transmit and receive certain radio frequencies. As a result, the wireless transmission may cause interference with other internal components of the portable computing device. 
     One method of shielding the wireless transmission includes a sponge-like foam material formed from a conductive material. However, the foam material may include a nonmatching appearance as compared to the appearance of structural features surrounding the foam material. As a result, the foam material intended only for functional use may nonetheless be visible, which is generally undesirable. Another solution is to use a solid material formed from a conductive material and having a uniform density, unlike the foam material. However, the solid material, when disposed between two housing structures of the electronic device, may be too rigid and therefore less likely to compress. As a result, one of the housing structures may deform or bow, which is also undesirable. Further, as the housing structures become thinner, their ability to resist deformation decreases. 
     SUMMARY 
     In one aspect, an electronic device is described. The electronic device may include an electrically conductive enclosure. The electronic device may further include an internal component disposed within the enclosure. In some embodiments, the internal component generates electromagnetic radiation. The electronic device may further include an antenna. The electronic device may further include a shield feature configured to shield the antenna from the electromagnetic radiation generated by the internal component. The shield feature may include an electrically conductive material engaging the enclosure. The shield feature may further include a non-electrically conductive material surrounding the electrically conductive material. 
     In another aspect, a shield feature for preventing transmission of electromagnetic radiation is described. The shield feature may include a first layer may include an electrically conductive material. The first layer may further include a first protrusion that includes a first tip region. The first layer may further include a second tip region. In some embodiments, the second protrusion may be separated from the first protrusion by a distance less than a wavelength of the electromagnetic radiation. The shield feature may further include second layer covering the first protrusion except for the first tip region. The second layer may further cover the second protrusion except for the second tip region. 
     In another aspect, a method for forming a shield feature suitable for preventing electromagnetic radiation from interfering with a component of an electronic device is described. The method may include forming a first protrusion, a second protrusion, and a base portion from a first layer of material that includes an electrically conductive material. The method may further include applying a second layer of material to the first protrusion, the second protrusion, and the base portion. The second layer may include a non-electrically conductive material. The method may further include removing a portion of the second layer of material to expose a first tip region of the first protrusion and a second tip region of the second protrusion. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure 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. 1  illustrates an isometric view of a traditional shield feature; 
         FIG. 2  illustrates a side view of an electronic device having several traditional shield features disposed in the electronic device; 
         FIG. 3  illustrates an isometric top view of a shield feature, in accordance with the described embodiments; 
         FIG. 4  illustrates an isometric bottom view of the shield feature shown in  FIG. 3 ; 
         FIG. 5  illustrates a cross sectional view of the shield feature shown in  FIG. 3  taken along line  5 - 5 ; 
         FIG. 6  illustrates a cross sectional view of the shield feature disposed between two substrates that form an enclosure or housing of an electronic device; 
         FIG. 7  illustrates a top isometric view of a first layer of an embodiment of a shield feature, in accordance with the described embodiments; 
         FIG. 8  illustrates a bottom isometric view of the shield feature in  FIG. 7 , showing the extensions formed from the first layer; 
         FIG. 9  illustrates an isometric view of the first layer of the shield feature shown in  FIG. 7 , with a second layer disposed on the first layer; 
         FIG. 10  illustrates an isometric view of the shield feature shown in  FIG. 9 , with a portion of the second layer removed; 
         FIG. 11  illustrates an isometric view of the shield feature shown in  FIG. 10 , with several vents formed and opening into each of the protrusions; 
         FIG. 12  illustrates an isometric view of the shield feature shown in  FIG. 11 , showing an adhesive layer secured with at least the first layer; 
         FIG. 13  illustrates an isometric view of an electronic device having a first antenna and a second antenna disposed in a clutch assembly; 
         FIG. 14  illustrates a partial isometric view of the electronic device shown  FIG. 13 , showing an interior region having a vent structure with a recessed region designed to receive a shield feature, in accordance with the described embodiments; 
         FIG. 15  illustrates plan view of the electronic device shown in  FIG. 13 , with shield features positioned between the antennas and several internal components of the electronic device; 
         FIG. 16  illustrates an enlarged view of the electronic device shown in  FIG. 15 , with the first shield feature preventing electromagnetic radiation transmitted by the first antenna from interfering with the first internal component; 
         FIG. 17  illustrates a top isometric view of an alternate embodiment of a shield feature, in accordance with the described embodiments; 
         FIG. 18  illustrates a bottom isometric view of the shield feature shown in  FIG. 17 ; 
         FIG. 19  illustrates a plan view of an interior region of a top case; 
         FIG. 20  illustrates an isometric view of an alternate embodiment of a shield feature; 
         FIG. 21  illustrates a cross sectional view of the shield feature shown in  FIG. 20  taken along line  21 - 21 ; 
         FIG. 22  illustrates a plan view of the interior region of the top case shown in  FIG. 19 , with a radio frequency (RF) shield disposed within the interior region; 
         FIG. 23  illustrates a cross sectional view of the top case shown in  FIG. 22  taken along line  23 - 23 ; and 
         FIG. 24  illustrates a flowchart showing a method for forming a shield feature suitable for preventing electromagnetic radiation from interfering with an internal component of an electronic device, in accordance with the described embodiments. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The following disclosure relates to shield features disposed in an electronic device and used to prevent passage of electromagnetic radiation to an internal component of the electronic device. The shield features may be referred to conductive gaskets formed from a compressible material that is also electrically conductive. The compressibility of the shield features prevents unwanted deformation or bowing of a structure with the shield features are engaged. 
     Traditional shield features used in electronic device have certain setback. For example,  FIG. 1  illustrates an isometric view of a traditional shield feature  100 . As shown, the traditional shield feature  100  may include electrically conductive material and further include a uniform density.  FIG. 2  illustrates a side view of an electronic device  110  having several traditional shield features disposed in the electronic device  110 . The partial cross sectional view  106  shows the traditional shield feature  100  in the electronic device  110 . The electronic device  110  includes a top case  112  and a bottom case  114  secured with the top case  112  by a fastener  116 . Ideally, an exterior surface of the bottom case  114  defines a generally planar surface. However, due to the rigidity and relative incompressibility of the traditional shield features disposed between fasteners, the bottom case  114  deforms, or bows, in locations associated with the traditional shield features. As a result, the exterior surface of the bottom case  114  is generally non-linear and extends beyond a planar surface. 
     In the following disclosure, a shield feature that forms part of a Faraday cage, or electromagnetic radiation shield, for an electronic device is described. The shield feature may include a base region having several protrusions. In some cases, these protrusions may include a conical shape. Also, each of the protrusions may include a hollow region that allows the protrusions to deform in response to a force exerted on the protrusions. For example, the protrusions allow a bottom case engaging the protrusions and coupled with the top case to deform the protrusions rather than deform the bottom case. 
     Also, the base region and the protrusions may include an electrically conductive material, such as a conductive silicone, to define an electrically conductive layer. Also, the electrically conductive material may initially be in liquid form and molded to a desired shape and size. Further, the electrically conductive material may undergo a compression molding by disposing the electrically conductive material in a mold cavity that defines a desired shape of at least a portion of the shield feature. In some embodiments, the mold cavity is heated and pressure is applied to the electrically conductive material to force the electrically conductive material to the various regions of the mold cavity. However, other molding techniques may include, but are not limited to, injection molding and pouring the liquid material into a mold cavity. The shield feature may further include a non-electrically conductive material, such as a non-conductive silicone, disposed over the electrically conductive material to define a non-electrically conductive layer. The non-electrically conductive layer may also be referred to as an electrically insulating layer. The non-electrically conductive material may be applied by spraying the non-electrically conductive material onto the electrically conductive material. Also, the non-conductive silicone may include a relatively dark color, including black. This allows the shield feature to be less visible to a user when the shield feature is disposed near an opening of the electronic device. 
     Some of the non-electrically conductive layer may be removed. For example, each of the protrusions may include a tip region that does not include the non-electrically conductive material. In some cases, a mask or template is placed over locations associated with the tip regions. After the non-electrically conductive layer is applied, the mask or template be removed to expose the tip regions which are formed from the electrically conductive layer. The tips regions are designed to contact an enclosure (such as a bottom case) of an electronic device. The enclosure may include one or more structures formed from a metal, such as aluminum. Also, if additional portions of the non-electrically conductive layer should be removed, a laser tool can laser ablate these areas to remove the additional portions. This allows the protrusions, which may deform when a force is applied to the tip regions, to nonetheless be in contact with the enclosure. 
     Also, opposite the tip regions, the electrically conductive layer may include several extensions, each of which may be located between adjacent protrusions. Each extension is designed to contact another structure of the enclosure, such as a top case. Also, in some cases, the shield feature includes an adhesive layer used to secure the shield feature one of the enclosure structures, such as the top case. The extensions may be further designed to extend beyond the adhesive layer to contact the top case. In this manner, the shield feature may extend from the bottom case to the top case. 
     Electronic device may include one or more internal components, such as an integrated circuit used to perform one or more functions in the electronic device. These internal components are known to generate electromagnetic radiation, or “noise,” which may interfere with other components of the electronic device, such as antenna. However, when one or more shield features are positioned between the antenna and a noise-generating internal component disposed in the enclosure, the one or more shield features may combine with the top case and the bottom case to define a Faraday cage enclosing the noise-generating internal component, and the antenna remains un-interfered with by the noise-generating internal component. In other words, electromagnetic radiation from the internal component does not cause electromagnetic interference with the antenna. 
     The protrusions are designed such that adjacent protrusions are positioned at a pitch, or distance, that is substantially less than a wavelength of the electromagnetic radiation. For example, a WiFi integrated radio circuit used for establishing a wireless Internet connection may transmit radio frequencies at approximately 5 GHz with a corresponding wavelength of approximate 12.5 centimeters. In some embodiments, the pitch between adjacent protrusions is 10 millimeters or less, which is significantly less than the wavelength of the radio frequencies associated with WiFi communication. Further, when the protrusions are deformed in response to the force applied to the protrusions, the pitch may change. Nonetheless, the pitch is significantly less than that of the wavelength of the radio frequencies associated with WiFi communication. Various mold cavities or injection molding apparatuses can be used to form a shield feature with a different pitch. Also, the pitch between adjacent protrusions may be adjusted to prevent different frequencies, greater than or less than 5 GHz, from extending through the shield feature. Alternatively, if it is desired that radio frequencies of a first frequency range pass through the shield feature and radio frequencies of a second frequency do not pass through the shield feature, the shield feature may be design such that the pitch between adjacent protrusions is greater than a wavelength associated with the first frequency but significantly less than a wavelength associated with the second frequency. 
     In addition to providing an electromagnetic shield, the shield feature, when in contact with the enclosure of the electronic device, can also be used as an electrical grounding pathway for one or more internal components in the electronic device. For example, the electronic device may include one or more internal components, such as an integrated circuit, each of which may include an electrical potential. Accordingly, the internal components include a relatively high frequency which may cause electromagnetic noise. However, when the internal components are electrically connected to the shield feature (or if each internal component is electrically connected to discrete shield features), the shield feature (or features) may provide an electrical grounding pathway for the internal components to the metal enclosure. 
     These and other embodiments are discussed below with reference to  FIGS. 3-24 . 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. 
       FIG. 3  illustrates an isometric top view of a shield feature  200 , in accordance with the described embodiments. The shield feature  200 , as shown, includes protrusions  210 , such as a first protrusion  212  and a second protrusion  214  (both of which may be representative of the remaining protrusions), disposed on a base portion  220 , with the base portion  220  surrounding the protrusions  210 . Each protrusion may include a tip region. For example, the first protrusion  212  includes a first tip region  216  and the second protrusion  214  includes a second tip region  218 . Although the protrusions  210  as shown include a discrete number, in other embodiments, the protrusions  210  include nine or more protrusions. Alternatively, in some embodiments, the protrusions  210  include seven or less protrusions. The protrusions  210  may take on several various shapes. However, in the embodiment shown in  FIG. 3 , the protrusions  210  generally include a conical shape that increase in diameter from the tip region to the base portion  220 . 
     The shield feature  200  may be formed from several layers of material. For example, in some embodiments, shield feature  200  includes a first layer and a second layer  234  disposed over the first layer. Also, in some embodiments, the first layer is formed from an electrically conductive material, such as a conductive silicone. The silicone may be electrically conductive by infusing small conductive particles, such as metal, into the silicone. The conductive material may be initially in liquid form and molded to a desired size and shape. Also, the electrically conductive layer may define the general shape of the shield feature  200 . This will be discussed below. The tip regions may be formed from the first layer, and accordingly, each tip region may be electrically conductive. 
     In some embodiments, the second layer  234  is an insulating or non-electrically conductive layer, such as a non-electrically conductive silicone. The second layer  234  may disposed on the first layer by spraying, molding, or other means generally known in the art for applying silicone-based materials. 
     The shield feature  200  may further include an adhesive layer  240 . In some embodiments, the adhesive layer  240  is formed from an electrically conductive material. In the embodiment shown in  FIG. 3 , the adhesive layer  240  is formed from a non-electrically conductive material, such as a non-electrically conductive pressure sensitive adhesive. This prevents an increase in electrical resistance when the shield feature  200  is disposed in an electronic device. Also, the shield feature  200  may include vents  250 , with each of protrusions  210  having a vent. For example, the first protrusion  212  includes a first vent  252 . The first protrusion  212  may include a hollow region (not shown) and the first vent  252  allows air to flow out of the hollow region to avoid pressure increases within the hollow region. This also facilitates compressibility of the protrusions  210 . 
       FIG. 4  illustrates an isometric bottom view of the shield feature  200  shown in  FIG. 3 . The shield feature  200  may include extensions  260  formed from the first layer of material, and accordingly, each of the extensions may be an electrically conductive extension, or electrode. Also, the first layer may extend from the tip regions (shown in  FIG. 3 ) to the extensions  260  such that the shield feature  200  includes electrically conductive material from end to end. As shown in the enlarged view, the extensions  260  include a first extension  262  (representative of the remaining extensions) that extends beyond the adhesive layer  240 . This ensures the first extension  262  engages a structure with which the shield feature  200  is secured (such as a top case of an enclosure). Several of the extensions  260  are located between adjacent protrusions. For example, the first extension  262  is located between the first protrusion  212  and the second protrusion  214 . 
       FIG. 5  illustrates a cross sectional view of the shield feature  200  shown in  FIG. 3  taken along line  5 - 5 . As shown, the first layer  232  may define the protrusions  210 , the tip regions and the extensions. Also, the first layer  232  extends from first end extension  264  to the second end extension  266 . The second layer  234  may be at least partially disposed over the first layer  232 . In some embodiments, the second layer  234  is dark including a black color, and accordingly, the shield feature  200  may be less visible to a user when the shield feature  200  is disposed in an electronic device. The second layer  234  may undergo a material removal process to remove a portion of the second layer  234  from the tip regions. For example, as shown, below the first tip region  216  of the first protrusion  212  is a first exposed region  226  of the first layer  232 , with the first exposed region  226  extending around the first tip region  216 . This ensures contact between the enclosure and the first tip region  216  and/or the first exposed region  226 . This will be shown and discussed below. 
     Each of the protrusions  210  may include a hollow region that includes a vent. For example, the first protrusion  212  includes a first hollow region  272  defined as a space or void between the first protrusion  212  and the adhesive layer  240 . Also, the first hollow region  272  may open to the first vent  252  (shown in  FIG. 4 ). The first hollow region  272  allows the shield feature  200  to compress when a force is applied to the first tip region  216  of the first protrusion  212 . Further, the conical shape of the first protrusion  212  defines a first angle  282  that allows the first protrusion  212  to include a lower compressibility force required to compress the first protrusion  212 . In order to further manipulate the compressibility, the thickness of the protrusion may be increases or decreased. For example,  FIG. 5  shows a third protrusion  222  having a thickness  288  representative of a thickness of the protrusions  210 . If the thickness  288  is increased, the compressibility force required to deform the third protrusion  222  increases while a thickness  288  that is decreased corresponds to a lesser compressibility force required to deform the third protrusion  222 . 
     Also, a pitch defined by a separation between adjacent protrusions may uniformly separate the protrusions  210 . For example, a pitch  290  separates the first protrusion  212  from the second protrusion  214 . In some embodiments, the pitch  290  is less than 10 millimeters. Further, in some embodiments, the pitch is less than 4 millimeters. The pitch  290 , representative of the pitch between remaining adjacent protrusions, is a distance significantly less than a wavelength of certain electromagnetic radiation. This allows the shield feature  200  (or one or more shield features) to form at least part of a Faraday cage for internal components of an electronic device. In this manner, electromagnetic radiation transmitted at 2.4 GHz (with an associated wavelength of approximately 12.5 centimeters), and even electromagnetic radiation transmitted at 5 GHz (with an associated wavelength of approximately 6 centimeters) is unable to pass or extend through the shield feature  200 . In some embodiments, the pitch  290  decreases to prevent electromagnetic radiation with higher frequencies from passing through the shield feature  200 . However, in other embodiments, the pitch  290  is altered to allow electromagnetic radiation transmitted at some frequencies to pass but not other frequencies. 
       FIG. 5  further shows a gap  294  defined as a space or void between adjacent protrusions and further defined between an imaginary line extending between the first protrusion  212  and the second protrusion  214 . It will be appreciated that the gap  294  includes a size and a shape designed to prevent transmission of unwanted electromagnetic radiation. 
       FIG. 6  illustrates a cross sectional view of the shield feature  200  disposed between two substrates that form part of an enclosure or housing of an electronic device. The enclosure may include a first substrate  302  and a second substrate  304 . In some embodiments, the first substrate  302  is a top case of an electronic device, and the second substrate  304  is a bottom case of an electronic device. Also, the first substrate  302  and the second substrate  304  may be formed from a metal, such as aluminum. This will be discussed below. As shown, the shield feature  200  is adhesively secured with the first substrate  302  via the adhesive layer  240 . Also, the first extension  262  and the first end extension  264  engage the first substrate  302  while the first tip region  216  of the first protrusion  212  engages the second substrate  304 . However, the second substrate  304  applies a force to the first protrusion  212  causing the first protrusion  212  to compress such that the first protrusion includes a second angle  284  less than the first angle  282  (shown in  FIG. 5 ). In this manner, the first protrusion  212  deforms, and the second substrate  304  does not deform or bow to remain generally flat. 
     Although the protrusions are designed to compress, in some cases, the tip region may become at least partially disengaged from the second substrate  304 . For example, when the second protrusion  214  is compressed, the second tip region  218  becomes at least partially disengaged with the second substrate  304 . However, because the second layer  234  includes a material removal process which defines a second exposed region  228  that extends around the second tip region  218 , the second protrusion  214  remains engaged with the second substrate  304  and functionality of the shield feature  200  is not compromised. 
       FIGS. 7-12  illustrates the steps for forming a shield feature.  FIG. 7  illustrates a top isometric view of a first layer  332  of an embodiment of a shield feature  300 , in accordance with the described embodiments. As shown, the first layer  332  may define protrusions  310  integrally formed with a base portion  320 . The phrase “integrally formed” as used throughout this detailed description and in the claims refers to two or more structures formed from as a single, unitary structure. For example, in some embodiments, the first layer  332  is formed from a silicone material initially in a liquid form and molded in a mold cavity or an injection molding tool. This also allows the first layer  332  to be formed from various shapes and sizes. Also, in some embodiments, the silicone is an electrically conductive silicone. Also, as shown, the base portion  320  extends around the protrusions  310 . In addition to the conductive material forming the basic structure of the protrusions  310 , the conductive material of the base portion  320  may allow for additional shielding of electromagnetic radiation. 
     A partial cross sectional view of a first protrusion  312 , representative of the remaining protrusion, shows a first hollow region  372  within the first protrusion  312 . Based upon the molding of the first layer  332 , a pitch between adjacent protrusions may be defined. For example, the pitch  390  is shown in  FIG. 7  between the first protrusion  312  and a second protrusion  314  adjacent to the first protrusion  312 . The pitch  390  may be any distance previously described for a pitch and accomplish one or more of the functionalities previously described. For example, the pitch  390  may be substantially less than a wavelength of electromagnetic radiation. 
       FIG. 8  illustrates a bottom isometric view of the shield feature  300  in  FIG. 7 , showing the extensions  360  formed from the first layer  332 . Accordingly, the extensions  360 , which include the first extension  362  and the first end extension  364 , may also be molded in a manner previously described and also formed from a conductive material, such as conductive silicone. 
       FIG. 9  illustrates an isometric view of the first layer  332  of the shield feature  300  shown in  FIG. 7 , with a second layer  334  disposed on the first layer  332 . In some embodiments, the second layer  334  is molded onto the first layer  332 . In the embodiment shown in  FIG. 3 , the second layer  334  is sprayed onto the first layer  332 . Also, in some embodiments, the second layer  334  is formed from silicone. Also, in some embodiments, the second layer  334  is a non-electrically conductive silicone. Further, in some embodiments, the second layer  334  includes a dark color, including a black color. The second layer  334  generally covers the entire exterior surface of the first layer  332 , including the protrusions  310  and the base portion  320  (shown in  FIG. 7 ). In the enlarged view of  FIG. 9  showing the partial cross section, the first protrusion  312  includes the first layer  332  covered by the second layer  334 . 
       FIG. 10  illustrates an isometric view of the shield feature  300  shown in  FIG. 9 , with a portion of the second layer  334  removed. In some embodiments, a mask or template (not shown) is disposed over the tip regions of the protrusions prior to disposing the second layer  334  over the first layer  332 , and then removed to expose the tip regions formed from the first layer  332 . In other embodiments, a laser tool (not shown) is used to laser ablate and remove portions of the second layer  334  to expose the tip region. The laser tool may also be used in conjunction with the mask or template. In the enlarged view of  FIG. 10  showing the partial cross section, the second layer  334  is removed from the first layer  332  such that the first tip region  316  of the first protrusion  312  and a first exposed region  326  around the first tip region  316  are exposed. In this manner, the first layer  332  is exposed in these locations. It will be appreciated that the remaining protrusions are formed in a manner previously described for the first protrusion  312 . 
       FIG. 11  illustrates an isometric view of the shield feature  300  shown in  FIG. 10 , with several vents  350  formed and opening into each of the protrusions  310 . In the enlarged view showing a partial cross section, the first protrusion  312 , representative of the remaining protrusions, includes a first vent  352  that extends from an exterior region of the shield feature  300  to the first hollow region  372  of the first protrusion  312 . This allows air to pass from the first hollow region  372  when, for example, a force is applied to the first protrusion  312 , thereby allowing the first protrusion  312  to deform. 
       FIG. 12  illustrates an isometric view of the shield feature  300  shown in  FIG. 11 , showing an adhesive layer  340  secured with at least the first layer  332  (shown in  FIG. 7 ) and disposed below the second layer  334 . The protrusions  310 , and in particular the tip regions and the exposes regions, include the first layer  332  extending beyond the second layer  334 . Also, the extensions  360  (shown in  FIG. 8 ) extend beyond the adhesive layer  340 . This allows the tip regions and the extensions to engage their respective regions of an enclosure of an electronic device. 
       FIG. 13  illustrates an isometric view of an electronic device  400  having a first antenna  402  and a second antenna  404  disposed in a clutch assembly  406 . In some embodiments, the electronic device  400  is a desktop computing device. In the embodiment shown in  FIG. 13 , the electronic device  400  is a laptop computing device. As shown, the electronic device  400  includes a lid portion  412  coupled with a base portion  414 . The lid portion  412  may include a display  416  designed to display visual content. The base portion  414  may include a keyboard  418  and a touch pad  422 , both of which are designed to input one or more gestures to the electronic device  400 . Also, the base portion  414  may include a top case  424  coupled with a bottom case (not shown). In some embodiments, the top case  424  and the bottom case are formed from a metal, such as aluminum. 
     The lid portion  412  may rotate or pivot with respect to the base portion  414  via the clutch assembly  406  and a hinge (not shown). Also, in order to receive the first antenna  402  and the second antenna  404 , the clutch assembly  406  is hollow. Further, the clutch assembly  406  is formed from a non-metal material that allows the first antenna  402  and the second antenna  404  to transmit and/or receive electromagnetic radiation. In addition, a cover  408  hiding the first antenna  402 , the second antenna  404 , and the clutch assembly  406  is also formed from a non-metal material. As shown in the enlarged view, the first antenna  402  includes a cable  410  electrically coupled with the first antenna  402  and extending through the clutch assembly  406  and a hinge to electrically couple with an integrated circuit (not shown) disposed in the base portion  414 . 
       FIG. 14  illustrates a partial isometric view of the electronic device  400  shown in  FIG. 13 , showing an interior region having a vent structure  432  with a recessed region  442  designed to receive a shield feature, in accordance with the described embodiments. The vent structure  432  is located proximate to a ledge feature  426  of the top case  424 , with the ledge feature  426  designed to receive a bottom case (not shown). Although not shown, the vent structure  432  may extend further along the top case  424  and designed to receive one or more additional shield features. 
       FIG. 15  illustrates plan view of the electronic device  400  shown in  FIG. 13 , with shield features positioned between the antennas and several internal components of the electronic device  400 , in accordance with the described embodiments. As shown, a first internal component  452  and a second internal component  454  are disposed between the top case  424  and a bottom case  428  coupled with the top case  424 . Several fasteners, such as a first fastener  430 , secure the top case  424  with the bottom case  428 . As shown, the vent structure  432  includes a first shield feature  502 , a second shield feature  504 , and a third shield feature  506 . The vent structure may include recessed regions (similar to the recessed region  442 , shown in  FIG. 14 ) for each of the shield features. When coupled with the top case  424 , the bottom case  428  engages the first shield feature  502 , the second shield feature  504 , and the third shield feature  506 . In this manner, the top case  424 , the bottom case,  428 , the first shield feature  502 , the second shield feature  504 , and the third shield feature  506  combine to define a Faraday case for the internal components of the electronic device  400 , which includes the first internal component  452  and the second internal component  454 . Accordingly, electromagnetic radiation in the form of radio frequencies generated internally with respect to the Faraday cage do not cause electromagnetic interfere with the components located externally with respect to the Faraday cage. 
       FIG. 15  further shows the cover  408 , including the first antenna  402  and the second antenna  404  disposed in the clutch assembly  406 , located externally with respect to the top case  424 , the bottom case  428  and the shield features. The cable  410  of first antenna  402  extends through a hinge  444  and electrically couples with a third internal component  456  which may be, for example, a WiFi integrated radio circuit or a Bluetooth integrated radio circuit. In some embodiments, the first internal component  452  and the second internal component  454  generate electromagnetic radiation capable of generating interference with other components of the electronic device  400 . For example, as shown, the first internal component  452  is capable of generating electromagnetic radiation  462  proximate to the first antenna  402 . Despite their potential sensitivity to electromagnetic interference, the first antenna  402  and the second antenna  404  are shielded from electromagnetic radiation from the first internal component  452  and the second internal component  454 , respectively, due to protection provided in part by the Faraday cage. As an example,  FIG. 16  illustrates an enlarged view of the electronic device  400  shown in  FIG. 15 , with the first shield feature  502  preventing electromagnetic radiation  462  transmitted by the first internal component  452  from interfering with the first antenna  402 . In this manner, the first antenna  402  may operate without interference from the electromagnetic radiation  462 . 
     The shield features may include different configurations. For example,  FIG. 17  illustrates a top isometric view of an alternate embodiment of a shield feature  600 , in accordance with the described embodiments. The shield feature may include protrusions  610  integrally formed with a base portion  620 . As shown, a first layer  632  is surrounded by a second layer  634 . In some embodiments, the first layer  632  is formed from an electrically conductive material, such as an electrically conductive silicone. Each of the protrusions  610  includes a tip region, with the first layer  632  extending through each of the tip regions. Accordingly, each of the tip regions may include at least some electrically conductive material. For example, the first protrusion  612  includes a first tip region  616 , at least a part of which is formed from the first layer  632 . Also, in some embodiments, the second layer  634  is formed from a non-electrically conductive material, such as a non-electrically conductive silicone. Unlike previous embodiments, the base portion  620  is substantially formed by the second layer  634  rather than the first layer  632 . However, the shield feature  600  may have other advantages. For example, the material defining the first layer  632  may be conserved. Also, in some cases, the first layer  632  may be co-molded with the second layer  634 . 
       FIG. 18  illustrates a bottom isometric view of the shield feature  600  shown in  FIG. 17 . As shown, the first layer  632  includes extensions  660 , including a first extension  662 . The extensions  660  and the tip regions of the protrusions  610  (shown in  FIG. 17 ) are designed to engage an enclosure in a manner previously described for a shield feature. Also, the shield feature  600  is designed to prevent electromagnetic radiation from passing through the shield feature  600 . In this manner, the pitch  690  (shown in  FIG. 17 ) is designed to be substantially less than a wavelength of the electromagnetic radiation to be blocked. 
       FIG. 19  illustrates a plan view of an interior region  702  of the top case  424  of an electronic device. The top case  724  may be substantially similar to, and may include any features of, the top case  424  shown in  FIG. 13 . As shown, the top case  724  includes a first protruding feature  732  and a second protruding feature  734 . Although shown in a particular location of the interior region  702 , the first protruding feature  732  and/or the second protruding feature  734  may be located in other regions of the interior region  702 . Also, in some embodiments, the interior region  702  includes three or more protruding features. 
     The first protruding feature  732  and the second protruding feature  734  may include a first internal region  742  and a second internal region  744 , respectively. In some embodiments, the first internal region  742  and the second internal region  744  are threaded. In this manner, the first internal region  742  and the second internal region  744  can each receive a threaded fastener designed to secure an internal component (not shown) with the top case  724 . However, in some embodiments, the internal component is an integrated circuit, such as a main logic board, that emanates electromagnetic radiation causing interference which may disrupt the functionality of other internal components. In some cases, an RF shield may be disposed between the internal component and a keyboard assembly (not shown) in order to prevent electromagnetic interference with one or more components associated with the keyboard assembly. However, the RF shield may include a number of openings corresponding to the number of protruding features (such as the first protruding feature  732 ). As such, the openings may create a path for the electromagnetic radiation to extend through the RF shield and interfere with the keyboard assembly components and/or other components. 
       FIG. 20  illustrates an isometric view of an alternate embodiment of a shield feature  800 . The shield feature  800  may include an electrically conductive region  802  surrounded by a non-electrically conductive region  804 . In some embodiments, the electrically conductive region  802  is formed from an electrically conductive material, such as an electrically conductive silicone previously described. Further, the electrically conductive region  802  may be formed by any process previously described for forming a feature for an electrically conductive material, such as compression molding. Also, the electrically conductive region  802  may further include an opening  812  extending through the electrically conductive region  802  and having a diameter that allows the shield feature  800  to receive, for example, the first protruding feature  732  (shown in  FIG. 19 ). The non-electrically conductive region  804  is designed to provide an electrical insulation layer and as well as enhance the cosmetic appearance of the shield feature  800 . Regarding the latter, in some embodiments, the non-electrically conductive region  804  includes a matte, or non-gloss, finish. In some embodiments, the non-electrically conductive region  804  is formed from a non-electrically conductive material, such as non-electrically conductive silicone. Also, the non-electrically conductive region  804  may be applied to the electrically conductive region  802  in any manner previously described for a non-electrically conductive deposition, such as spraying. 
       FIG. 21  illustrates a cross sectional view of the shield feature  800  shown in  FIG. 20  taken along line  21 - 21 . As shown, the electrically conductive region  802  includes several contoured regions designed to include a shape generally similar to that of a protruding feature (such as the first protruding feature  732 , shown in  FIG. 19 ). This allows for a close form fit between the electrically conductive region  802  and the (metal) protruding feature. Further, the electrically conductive region  802  may be formed from a material or materials that is/are compliant in order to further increase the form fit between the electrically conductive region  802  and a protruding feature. Also, a top portion  822  of the electrically conductive region  802  may be approximately co-planar, or flush, with respect to a top portion  824  of the non-electrically conductive region  804 . In this manner, an internal component can readily be in electrical contact with the electrically conductive region  802  and the electrically conductive region  802  can define a portion of an electrically grounding pathway for the internal component. This will be shown below. 
       FIG. 22  illustrates a plan view of the interior region  702  of the top case  724  shown in  FIG. 19 , with an RF shield  900  disposed within the interior region  702 . As shown, the RF shield  900  is disposed between an internal component  910  and a keyboard assembly  920 . Also, the internal component  910  is secured with the top case  724  via a first fastener  932  and a second fastener  934 , with the first fastener  932  and the second fastener  934  extending through the first internal region  742  and the second internal region  744  (shown in  FIG. 19 ), respectively. In some embodiments, the internal component  910  is an integrated circuit, such as a main logic board. The RF shield  900  is designed to shield the keyboard assembly  920  and/or other components from electromagnetic radiation generated by the internal component  910 . When the RF shield  900  includes openings designed to receive, for example, the first protruding feature  732  and the second protruding feature  734 , the RF shield  900  may be ineffective in shielding electromagnetic radiation in locations corresponding to the openings. However, when a shield feature, such as the shield feature  800  shown in  FIG. 20 , is disposed around the protruding features designed to receive the internal component  910 , the electromagnetic radiation generated from the internal component  910  may be prevented, or substantially blocked, from extending to components associated with the keyboard assembly  920  and/or other components, and the keyboard assembly  920  and/or other components may achieve its desired functionality without electromagnetic interference. 
       FIG. 23  illustrates a cross sectional view of the top case  724  shown in  FIG. 22  taken along line  23 - 23 . As shown, the first fastener  932  is secured with the first protruding feature  732  to secure the internal component  910  with the top case  724 . Also, an electrical grounding pad  830  may be disposed between the first fastener  932  and the internal component  910 . Also, the shield feature  800  is secured with the RF shield  900 , defined by several layers, via an adhesive layer  840 . In some embodiments, the adhesive layer  840  is an electrically conductive adhesive. Further, as shown in the enlarged view, the electrically conductive region  802  of the shield feature  800  includes a contoured region designed to leave minimal space between the first protruding feature  732  of the top case  724  and the electrically conductive region  802 . In this manner, electromagnetic radiation  952  emitted from the internal component  910  is prevented, or substantially limited, from extending through the opening of the RF shield  900 . 
     Also, in some embodiments, the RF shield  900  includes a first layer  902 . In some embodiments, the first layer  902  is an electrically conductive layer. In this manner, an electrically grounding pathway for the internal component  910  may be defined in part by the electrical grounding pad  830 , the electrically conductive region  802  of the shield feature  800 , the adhesive layer  840 , and the first layer  902 . Accordingly, the shield feature  800  can be used not only as an electromagnetic radiation shield for a keyboard assembly  920 , but also as an electrical grounding feature for an internal component  910 . 
       FIG. 24  illustrates a flowchart  1000  showing method for forming a shield feature suitable for preventing electromagnetic radiation from interfering with an internal component of an electronic device, in accordance with the described embodiments. In step  1002 , a first protrusion, a second protrusion, and a base portion are formed from a first layer of material. In some embodiments, the first layer of material is an electrically conductive material, such as an electrically conductive silicone. Also, in some embodiments, forming the first protrusion, the second protrusion, and the base portion includes molding, such as using a mold cavity or an injection molding apparatus. Also, a pitch may separate the first protrusion and the second protrusion. The pitch may be a distance substantially less than a wavelength of the electromagnetic radiation. 
     In step  1004 , a second layer of material is applied to the first protrusion, the second protrusion, and the base portion. In some embodiments, the second layer of material is molded over the first protrusion, the second protrusion, and the base portion. In other embodiments, the second layer of material is sprayed over the first protrusion, the second protrusion, and the base portion. Also, in some embodiments, the second layer of material is formed from a non-electrically conductive material, such as a non-electrically conductive silicone. Also, the second layer of material may include a dark, or black, color. 
     In step  1006 , a portion of the second layer of material is removed to expose a first tip region of the first protrusion and a second tip region of the second protrusion. The first tip region and the second tip region are formed from the first layer of material, and accordingly, may include an electrically conductive material. The removal means may include masking each tip regions with a mask prior to applying the second layer of material, followed by removing the masks after applying the second layer of material. Alternately, or in combination, a laser tool can perform a laser ablation to the tip regions to remove the second layer of material. Also, the laser tool can laser ablate additional material of the second layer to define exposed regions surrounding the tip regions. 
     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, HDDs, DVDs, magnetic tape, and optical data storage devices. 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 described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments 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.

Metadata:
Filing Date: 20150422
Publication Date: 20170919
Grant Date: 20170919
Priority Date: 20150422
Inventors: SMITH BRANDON S.
TATE THOMAS R.
SALVADOR Mark A.
CALKINS ALEXANDER C.
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1698", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/2266", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/526", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/2266", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1698", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/526", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 57147698