PATENT DOCUMENT

Publication Number: US-10015297-B2
Application Number: US-201615260222-A
Country: US
Kind Code: B2

Title: Display cover retention features for a portable electronic device

Abstract:
An electronic device having a cover glass secured with a frame is disclosed. The electronic device includes a masking layer positioned between the cover glass and the frame. The masking layer may include several ink layers. The pigment composition of one of the ink layers may be altered in order to improve an adhesive bond between the ink layer and the cover glass. The frame can be modified to enhance an adhesive bond between the masking layer and the frame. For example, the frame can be altered to include a porous region to increase the surface area of the frame such that the adhesive can bond to the additional surface area. The frame may also include an extension, or rib, that may increase the surface area of the frame that receives an adhesive. The frame may include an opening or a cavity that assists in assembly between an insert-molded feature.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a frame member; 
 a transparent cover carried by the frame member; 
 a masking layer positioned at an interface between the frame member and the transparent cover, the masking layer comprising:
 a first layer bonded to the transparent cover, the first layer including a first type pigment and a first amount of resin, and 
 a second layer that includes the first type pigment and a second amount of resin different from the first amount of resin; and 
 
 an adhesive layer that bonds the masking layer with the frame member. 
 
     
     
       2. The electronic device of  claim 1 , wherein the frame member comprises a porous region, and wherein the adhesive layer is at least partially disposed in the porous region. 
     
     
       3. The electronic device of  claim 1 , further comprising:
 a display assembly; and 
 a display frame, wherein the display assembly and the display frame are covered by the transparent cover, and wherein the display frame includes a color resembling a color associated with the first type pigment. 
 
     
     
       4. The electronic device of  claim 1 , wherein:
 the frame member comprises a rib having a first surface, a second surface, and a third surface, and 
 the adhesive layer is disposed on the first surface, the second surface, and the third surface. 
 
     
     
       5. An electronic device having a display assembly and a display frame bordering the display assembly, the electronic device comprising:
 a protective cover overlaying the display assembly and the display frame; 
 a cover support member having a support surface that receives an adhesive layer to secure the cover support member with the protective cover, the support surface having a porous region that receives the adhesive layer; and 
 a masking layer positioned at an interface between the protective cover and the cover support member to prevent light transmission through the interface. 
 
     
     
       6. The electronic device of  claim 5 , wherein the support surface comprises a primer agent disposed on the support surface that alters the support surface to form the porous region. 
     
     
       7. The electronic device of  claim 5 , wherein the support surface comprises a rib formed on the support surface, the rib including a first surface and a second surface perpendicular to the first surface. 
     
     
       8. The electronic device of  claim 7 , wherein the adhesive layer is disposed on the first surface and the second surface. 
     
     
       9. The electronic device of  claim 8 , wherein the rib further comprises a third surface different from the first surface and the second surface, wherein the adhesive layer is disposed on the third surface. 
     
     
       10. The electronic device of  claim 5 , wherein the support surface comprises a series of peaks and valleys, and wherein the adhesive layer is disposed on the series of peaks and valleys. 
     
     
       11. The electronic device of  claim 5 , wherein the masking layer is directly secured to the protective cover, and wherein the masking layer comprises:
 a first layer including a first composition having a first type pigment, and 
 a second layer including a second composition having the first type pigment, the second composition different from the first composition. 
 
     
     
       12. The electronic device of  claim 11 , wherein:
 the first composition comprises the first type pigment and a first amount of resin, and 
 the second composition comprises the first type pigment and a second amount of resin less than the first amount of resin. 
 
     
     
       13. A method for assembling an electronic device having a first part and a second part secured with the first part, the method comprising:
 disposing a first layer along the first part, the first layer including a first composition having a first type pigment; 
 disposing a second layer on the first layer, the second layer including a second composition having the first type pigment, the second composition different from the first composition, wherein the first layer and the second layer combine to define a masking layer at an interface between the first part and the second part to prevent light transmission through the interface; and 
 providing a display frame that includes a color resembling a color associated with the first type pigment. 
 
     
     
       14. The method of  claim 13 , wherein disposing the masking layer comprises:
 forming the first composition with the first type pigment and a first amount of resin, and 
 forming the second composition comprises the first type pigment and a second amount of resin less than the first amount of resin. 
 
     
     
       15. The method of  claim 13 , further comprising:
 forming a porous region on the second part; and 
 applying an adhesive layer to the second part, wherein the adhesive layer is at least partially disposed in the first part. 
 
     
     
       16. The method of  claim 13 , further comprising:
 forming a series of peaks and valleys on the second part; and 
 applying an adhesive layer to the second part, wherein the adhesive layer is at least partially disposed on the series of peaks and valleys. 
 
     
     
       17. The method of  claim 13 , where the first part comprises a cover glass, and wherein the second part comprises a frame member. 
     
     
       18. The electronic device of  claim 1 , further comprising an enclosure that secures with the frame member, the enclosure defining an internal volume that carries operational components. 
     
     
       19. The electronic device of  claim 1 , wherein:
 the first amount of resin is greater than the second amount of resin, 
 the first layer provides a first adhesive bond, and 
 the second layer provides a second adhesive bond that is less than the first adhesive bond. 
 
     
     
       20. The electronic device of  claim 1 , wherein the masking layer further comprises:
 a third layer bonded to the second layer; 
 a fourth layer bonded to the third layer, wherein the third layer and the fourth layer include the first type pigment; and 
 a fifth layer bonded to the fourth layer and the frame member, the fifth layer comprising a pigment type different from the first type pigment.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/215,531, filed on Sep. 8, 2015, and titled “DISPLAY COVER RETENTION FEATURES FOR A PORTABLE ELECTRONIC DEVICE,” the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The following description relates to an electronic device. In particular, the following description relates to techniques used to adhere a display cover, such as a cover glass, with a frame used to support the display cover. The adhesions techniques can be based in part on the aesthetic appearance of the electronic device. 
     BACKGROUND 
     Electronic device may include a cover glass secured with an enclosure to house several components. A frame may be used to secure the cover glass with the enclosure, and may also be positioned between the cover glass and the enclosure. In some cases, the cover glass includes a material applied to the cover glass and positioned between the cover glass and the enclosure. Also, the material can include opaque properties to minimize or prevent light from passing between the cover glass and the enclosure. 
     However, the material includes some drawbacks. For example, the material may reduce an adhesive bond between the cover glass and the frame, thereby increasing the likelihood of the cover glass delaminating from, or becoming unsecured with, the frame in the event of a load or force to the electronic device. As a result, the cover glass is susceptible to becoming detached from the electronic device. 
     SUMMARY 
     In one aspect, an electronic device having a first part and a second part secured with the first part is described. The electronic device may include a masking layer positioned at an interface between the first part and the second part to prevent light transmission through the interface. The masking layer may include a first layer including a first composition having a first type pigment. The masking layer may further include a second layer including a second composition having the first type pigment. The second composition may be different from the first composition. 
     In another aspect, an electronic device having a display assembly and a display frame bordering the display assembly is described. The electronic device may include a protective cover assembly overlaying the display assembly and the display frame. The electronic device may further include a cover support member having a support surface that receives an adhesive layer to secure the cover support member with the protective cover. The support surface may include a porous region that receives the adhesive layer. The electronic device may further include a masking layer positioned at an interface between the protective cover and the cover support member to prevent light transmission through the interface. 
     In another aspect, a method for assembling an electronic device having a first part and a second part secured with the first part is described. The method may include disposing a first layer along the first part. The first layer may include a first composition having a first type pigment. The method may further include disposing a second layer on the first layer. The second layer may include a second composition having the first type pigment. Also, the second composition may be different from the first composition. In some embodiments, the first layer and the second layer combine to define a masking layer at an interface between the first part and the second part to prevent light transmission through the interface. 
     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 an embodiment of an electronic device, in accordance with the described embodiments; 
         FIG. 2  illustrates an exploded view of the electronic device shown in  FIG. 1 , showing several internal features of the electronic device; 
         FIG. 3  illustrates a cross sectional view of the masking layer shown in  FIG. 2 , showing various layers of the masking layer, in accordance with the described embodiments; 
         FIG. 4  illustrates a cross sectional view of the electronic device, showing the protective cover adhesively secured with the cover support member; 
         FIG. 5  illustrates a cross sectional view of an electronic device, with a primer agent applied to a cover support member; 
         FIG. 6  illustrates a cross sectional view of the electronic device shown in  FIG. 5 , with a protective cover adhesively secured with the cover support member; 
         FIG. 7  illustrates a cross sectional view of a cover support member in a molding tool used to mold the cover support member; 
         FIG. 8  illustrates a cross sectional view of an electronic device, showing a protective cover adhesively secured with the cover support member formed in  FIG. 7 ; 
         FIG. 9  illustrates a cross sectional view of an electronic device, showing a cover support member having a rib extending from the cover support member; 
         FIG. 10  illustrates a cross sectional view of the electronic device shown in  FIG. 9 , further showing a protective cover adhesively secured with the cover support member; 
         FIG. 11  illustrates a plan view of a cover support member including an attachment feature disposed in the cover support member; 
         FIG. 12  illustrates a cross sectional view of an electronic device having a cover support member shown in  FIG. 11 ; 
         FIG. 13  illustrates a cross sectional view of the electronic device shown in  FIG. 12 , showing a protective cover secured with the cover support member; and 
         FIG. 14  illustrates a flowchart showing a method for assembling 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 an electronic device having an enhanced adhesive masking layer between a protective cover and a frame that carries the protective cover. The protective cover may include a transparent layer that overlays and protects a display assembly of the electronic device. In order to prevent light transmission between the protective cover and the frame, the protective cover may receive several layers of material designed to provide an opaque mask, as well as enhance an appearance of the electronic device. Regarding the latter, the masking layer may include an appearance, in terms of color, similar to that of a display frame that borders the display assembly. Also, the masking layer can hide or obscure a location between the protective cover and the frame in order to cover an adhesive layer, for example, used in conjunction with the masking layer. 
     In some embodiments, the masking layer includes several layers of ink. Each ink layer may include pigments that define the color of the ink, and accordingly, define the color of the layer. While the pigments contribute to the appearance of the ink layer, and in turn, the electronic device, the pigments provide the ink layer with relatively little adhesive forces to bond the mask to the protective cover, even when the ink layer includes some resin material. Accordingly, a force exerted on the electronic device may cause masking layer to tear, or otherwise become removed, from the structural component. 
     In order to strengthen the adhesive bond of the masking layer to the protective cover, the ratio of pigments to resin of some layers can be altered. For example, the masking layer may include at least one ink layer designated as a bonding layer that bonds directly to the structural component. The bonding layer can include additional resin as well as a reduced amount of pigments. Accordingly, the bonding layer includes a relatively high resin-to-pigment ratio (or conversely, a relatively low pigment-to-resin ratio) as compared to the remaining layers of the masking layer. Due to the increased resin material, the masking layer may include an enhanced adhesive bond with the protective cover by way of the bonding layer. However, the bonding layer, having fewer pigments, results in less overall pigmentation of the masking layer, and accordingly, the appearance of the bonding layer, in terms of color, is reduced. In this regard, the masking layer may include additional layers of relatively high pigment-to-resin layers that compensate for the bonding layer to enhance both the appearance of the masking layer and the light blocking capabilities of the masking layer. 
     In addition to altering the ink, the frame may include modifications to enhance a bond with an adhesive layer applied to the frame that is used to bond with the masking layer, and in some cases, the masking layer and the protective cover. For example, prior to adding the adhesive layer, the frame may be pre-treated with a primer agent that alters a surface energy, or surface tension, of the frame to enhance a bond with the adhesive layer. In this regard, the frame may become relatively porous, which allows the adhesive layer to extend through to least some of the porous regions. The bond may include a chemical bond that is improved by the primer agent. 
     Alternatively, or in combination, a mold cavity (used to mold the frame) may be modified in order to increase a surface roughness of the frame. An electrical discharge machining (“EDM”) operation, which can also include chemical etching, can be used on the mold cavity to change one or more surfaces of the mold cavity, which in turn changes one or more corresponding surfaces of the frame. 
     The frame may also be modified in order to provide additional surface area with which the adhesive layer may bond. For example, the frame may include a rib or extension that protrudes in a direction toward the protective cover. The adhesive layer may be applied or disposed at a location corresponding to the rib. Then, when the protective cover (or ink layer, if applicable) engages the frame, the adhesive layer extends across multiple surfaces (both horizontal and vertical) of the rib and cures. In this manner, the adhesive layer is bonded to multiple surfaces of the rib, creating a bond that resists at least some lateral or shear forces exerted on the electronic device. Accordingly, the adhesive bond may enhance resistance against a load or force to the protective cover, as the tensile strength of the adhesive bond may counteract the load or force to the protective cover. 
     Also, the frame may include additional modifications. For example, the frame may include several cavities, or wells, in the frame designed to receive an additional adhesive layer (or layers) that fill the cavities to create regions of greater adhesive thickness. The resultant shape of the adhesive, based in part on the shape of the cavities, may create adhesive protrusions that to resist delamination, or uncoupling, between the frame and the protective cover. 
     These and other embodiments are discussed below with reference to  FIGS. 1-14 . 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. 1  illustrates an isometric view of an embodiment of an electronic device  100 , in accordance with the described embodiments. In some embodiments, the electronic device  100  is a tablet device. In the embodiment shown in  FIG. 1 , the electronic device  100  is a mobile communication device, such as a smartphone. The electronic device  100  may include an enclosure  102  designed to enclose several operational components (not shown), including integrated processor circuits, memory circuits, a speaker, a microphone, etc. In some embodiments, the enclosure  102  is formed from a metal, such as aluminum. The enclosure  102  may include a rear portion and several sidewalls extending from the rear portion to define an internal cavity to receive the operational components. 
     The electronic device  100  may further include a display assembly  104  designed to display visual content. The display assembly  104  may include a touch-sensitive layer (not shown) integrated with the display assembly  104  such that the display assembly  104  may receive and respond to a touch input by a user. Further, the touch-sensitive layer may include a capacitive touch sensitive layer that may receive and respond to a capacitive coupling with the capacitive touch sensitive layer. A display frame  106  may surround the display assembly  104 . The display frame  106  may enhance an overall appearance of the electronic device  100  by providing a border around the display assembly  104  to cover one or more components. Further, the appearance, including color, of the display frame  106  may vary in order to provide an electronic device of different appearances, allowing a user to select one of several appearances. Although not labeled, a protective cover may overlay the display assembly  104  and the display frame  106 . The protective cover may include a transparent material, such as glass or sapphire as non-limiting examples, which provides a light-transmissible outer protective layer. 
     Also, the electronic device  100  may further include a button  108  designed to receive an additional input allowing a user to provide a control to the electronic device  100  that controls, for example, a software application or “app” visually presented on the display assembly  104 . The electronic device  100  may include an internal power source (such a battery) used to provide power in the form of electrical current to several operational components of the electronic device  100 . Accordingly, the electronic device  100  may include a charging port  110  designed to receive power in order to provide power to the internal power supply and/or the operational components. Also, although not shown, the electronic device  100  may include one or more control inputs (such as button) disposed in various locations along the enclosure  102 , with the control inputs offering different control features for the electronic device  100 . 
       FIG. 2  illustrates an exploded view of the electronic device  100  shown in  FIG. 1 , showing several internal features of the electronic device  100 . For purposes of simplicity and illustration, several feature of the electronic device  100  are removed. As shown, the display frame  106  may provide border around the display assembly  104 . The display frame  106  may come in a variety of appearances. For example, in some embodiments, the display frame  106  includes an appearance of a white display frame. In other words, the display frame  106  is white in color. In other embodiments, the display frame  106  includes an appearance of a black display frame. Other appearances are possible. 
     Also, the display assembly  104  and the display frame  106  may be overlaid by a protective cover  112 , which may be formed from a transparent material, such as glass or sapphire. When the electronic device  100  is assembled, the protective cover  112  can be seated on a cover support member  114 . The cover support member  114  may be referred to as a frame that provides structural support for the display assembly  104 , the display frame  106 , and/or the protective cover  112 . In some embodiments, the cover support member  114  includes a polymeric material, such as plastic. Also, the cover support member  114  may include a support surface  116  designed to receive the protective cover  112 . In some embodiments, the protective cover  112  is bonded with the cover support member  114  at the support surface  116  by an adhesive layer (not shown). 
     As shown in the enlarged view, the electronic device  100  may include a masking layer  120 . The masking layer  120  exaggerated in size and enlarged in  FIG. 2  for purposes of illustration. The masking layer  120  may be positioned at an interface between the protective cover  112  and the cover support member  114 . In some embodiments, the masking layer  120  includes several layers applied to a rear portion (not shown) of the protective cover  112 . Further, each layer of the masking layer  120  may be applied by a screen-printing operation, as a non-limiting example. In this regard, in some embodiments, the masking layer  120  includes several layers of ink, or ink-based materials. Also, the masking layer  120  may provide an opaque masking feature that limits or prevents light from passing between the protective cover  112  and the cover support member  114 . Each of the layers may include a composition of pigments to define the color of each layer, and also a resin material to provide bonding energy between the pigments. However, in some embodiments, the composition of at least one of the layers differs from the remaining layers by, for example, having an increased amount of resin material and fewer pigments. This will described below. 
     Also, the cover support member  114  may include several features protruding from the cover support member  114 , and designed to engage with features of the enclosure  102  to secure the cover support member  114  with the enclosure  102 . For example, a first attachment feature  132  and a second attachment feature  134  may be partially embedded in the cover support member  114  and designed to couple with a first securing feature  136  and a second securing feature  138 , respectively, of the enclosure  102 . In some embodiments, the first attachment feature  132  and the second attachment feature  134  are formed from a metal. Further, the first attachment feature  132  and the second attachment feature  134  may be insert-molded into the cover support member  114 , which may include molding the cover support member  114  and inserting the first attachment feature  132  and the second attachment feature  134  prior to curing the cover support member  114 . This will be discussed below. 
     Also, as shown in  FIG. 2 , the enclosure  102  may include a support surface  142  that receives the cover support member  114 . When the protective cover  112  is secured with the cover support member  114 , with the masking layer  120  positioned between the protective cover  112  and the cover support member  114 , the cover support member  114  may be adhesively secured with the enclosure  102  at a location defined by the support surface  142 . 
       FIG. 3  illustrates a cross sectional view of the masking layer  120  shown in  FIG. 2 , showing various layers of the masking layer, in accordance with the described embodiments. The masking layer  120  may include a first layer  122 . The first layer  122  may be referred to as an uppermost layer of the masking layer  120  designed to bond with the protective cover  112  (shown in  FIG. 2 ). The masking layer  120  may further include a second layer  124  secured with the first layer  122 . The first layer  122  and the second layer  124  may include ink material, or some other pigmented material. Accordingly, the color of the first layer  122  and the second layer  124  may be determined by a pigmentation applied to the ink used to form the first layer  122  and the second layer  124 . The layers may be referred to as cosmetic layers based in part on their matching appearance with that of the display frame  106  (shown in  FIG. 2 ). In this regard, in some embodiments, the first layer  122  and the second layer  124  may include a color substantially similar to that of the display frame  106 . For example, in some embodiments, the display frame  106 , the first layer  122 , and the second layer  124  are black, or include a black appearance. In other embodiments, the display frame  106 , the first layer  122 , and the second layer  124  are white, or include a white appearance. Other colors are also possible. 
     Also, at least some of the aforementioned layers may include a resin material to enhance an adhesive bond between adjacent layers as well as enhance a bond with a structural component to which the masking layer  120  is bonded, such as the protective cover  112  (shown in  FIG. 2 ). Further, in order to create adhesive forces between the structural component and the masking layer  120 , the first layer  122  may include a composition having fewer pigments and a greater amount of resin, as compared to the second layer  124 . Accordingly, the pigment-to-resin ratio of the first layer  122  is less than that of the second layer  124 . Conversely, however, the resin-to-pigment ratio of the first layer  122  is greater than that of the second layer  124 . In this regard, the first layer  122  may provide the masking layer  120  with an enhanced adhesive bond with the structural component to reduce or prevent the masking layer  120  from delaminating, or uncoupling, from the structural component in the event of a load or force to the electronic device  100  (shown in  FIG. 2 ). However, the second layer  124  can at least partially compensate for the reduced amount of pigments of the first layer  122 . 
     Also, the masking layer  120  may include additional layers, such as a third layer  126 , a fourth layer  128 , and a fifth layer  130 . Further, the third layer  126 , the fourth layer  128 , and the fifth layer  130  may increase the opacity of the masking layer  120  to enhance the light-blocking capabilities of the masking layer  120 . The third layer  126  and the fourth layer  128  may also include an appearance or color similar to that of the first layer  122  and the second layer  124 . In this regard, the same pigmentation used in the first layer  122  and the second layer  124  may also be present in the third layer  126 , the fourth layer  128 , and the fifth layer  130 . However, the composition of pigments and resin material may generally resemble that of the second layer  124  as opposed to the first layer  122 . Further, in some instances, the fifth layer  130  includes a pigmentation that provides a darker appearance than the remaining layers. For example, the fifth layer  130  may include pigmentation that provides a gray appearance in order to further enhance the opacity of the masking layer  120 . While a discrete number of layers are shown, the masking layer  120  may include a different number of layers. Further, the number of layers of the masking layer  120  may be based in part upon the color selected for the display frame  106 . 
       FIG. 4  illustrates a cross sectional view of the electronic device  100 , showing the protective cover  112  adhesively secured with the cover support member  114 . Several operational components are removed for simplicity. As shown in the enlarged view, the masking layer  120  may be secured with the protective cover  112  by way of an adhesive bond between the first layer  122  and the protective cover  112 . The masking layer  120  may also be bonded with the cover support member  114  by an adhesive layer  140 , and the protective cover  112  is secured with the cover support member  114  by way of the masking layer  120  and the adhesive layer  140 . As shown, the adhesive layer  140  may engage both the masking layer  120  and the cover support member  114 . However, in other embodiments, the adhesive layer  140  extends from the cover support member  114  to the protective cover  112 . Also, as shown in the enlarged view, the protective cover  112  may be secured with an the cover support member  114  in a manner such that an exterior surface of the protective cover  112  is co-planar, or approximately co-planar, with respect to an exterior surface of the cover support member  114 . Although not shown, the cover support member  114  may be adhesively secured with the enclosure  102 . 
       FIGS. 5-13  show and describe variations and modifications to a cover support member, similar to that of the cover support member  114  shown in  FIG. 2 . It will be appreciated that electronic device shown in  FIGS. 5-13  may include any feature or features previously described for an electronic device  100 , shown in  FIGS. 1-3 . 
     Some modifications may increase an adhesive bond between a protective cover and a cover support member, and in particular, between at least one of the layers of material (of a masking layer) and the cover support member. For example,  FIG. 5  illustrates a cross sectional view of an electronic device  200 , with a primer agent  202  applied to a cover support member  214 . The primer agent  202  may increase a surface energy, or surface tension, of the cover support member  214 , thereby enhancing a bond between the cover support member  214  and an adhesive applied to the cover support member  214 . The primer agent  202  may also change a chemical composition of the cover support member  214  in order to increase the surface energy, or surface tension. Further, the primer agent  202  may also increase the porosity of the cover support member  214 . For example, as shown in  FIG. 5 , the cover support member  214  may include a first porous region  216  and a second porous region  218 , both of which are representative of several, additional porous regions (not shown). This may allow an adhesive to extend through the cover support member  214  via the porous regions. 
       FIG. 6  illustrates a cross sectional view of the electronic device  200  shown in  FIG. 5 , with a protective cover  212  adhesively secured with the cover support member  214 . As shown, the protective cover  212  is secured with the cover support member  214  by way of a masking layer  220  and an adhesive layer  240 . The masking layer  220  may include several layers having properties previously described, with an uppermost layer  222  adhesively secured with the protective cover  212  and a lowermost layer  230  adhesively secured with the adhesive layer  240 . Also, as shown, the masking layer  220  includes several layers between the uppermost layer  222  and the lowermost layer  230  bonded therewith. As a result of the primer agent  202 , the adhesive layer  240  may extend into the porous regions (previously described) of the cover support member  214  such that the adhesive layer  240  is disposed across an increased surface area of the cover support member  214  (as opposed to a planar surface). The additional surface area by which the adhesive layer  240  is bonded allows for an enhanced bond between the cover support member  214  and the masking layer  220 , and as a result, a stronger bond is formed between the protective cover  212  and the cover support member  214 . This may prevent a delamination between the adhesive layer  240  and the cover support member  214  in the event of a load or force to the electronic device  200 . Also, in the event that the protective cover  212  does not include the masking layer  220 , the protective cover  212  may be directly secured with the cover support member  214  via the adhesive layer  240 . 
     Additional or alternate modifications may be made to a cover support member. For example,  FIG. 7  illustrates a cross sectional view of a cover support member  314  in a molding tool  350  used to mold the cover support member  314 . The molding tool  350  may be designed to receive a polymeric material such that, when cured, forms the cover support member  314  in accordance with the described embodiments. However, as shown in the enlarged view, the molding tool  350  may include a non-coplanar surface  352 . The non-coplanar surface  352  may also be referred to as a saw tooth surface having a region of peaks and valleys. Accordingly, when the polymeric material is cured within the molding tool  350 , the polymeric material may form a non-coplanar surface  316  having peaks and valleys corresponding to the peaks and valleys of the non-coplanar surface  352  of the molding tool  350 . 
       FIG. 8  illustrates a cross sectional view of an electronic device  300 , showing a protective cover  312  adhesively secured with the cover support member  314  formed in  FIG. 7 . As shown in the enlarged view, an adhesive layer  340  may be disposed positioned between the masking layer  320  and the cover support member  314 . As a result of an increased surface area and surface roughness of the cover support member  314 , an enhanced adhesive bond between the adhesive layer  340  and the cover support member  314  can be provided (as compared to a flat or co-planar surface of a cover support member). Also, in the event that the protective cover  312  does not include the masking layer  320 , the protective cover  212  may be directly secured with the cover support member  314  via the adhesive layer  340 . 
       FIG. 9  illustrates a cross sectional view of an electronic device  400 , showing a cover support member  414  having a rib  416  extending from the cover support member  414 . The rib  416  may be formed during a molding operation of the cover support member  414  such that the rib  416  is integrally formed with the cover support member  414 . The rib  416  may the cover support member  414  with additional surface area, thereby allowing for an additional region to which an adhesive may bond. For example,  FIG. 10  illustrates a cross sectional view of the electronic device  400  shown in  FIG. 9 , further showing a protective cover  412  adhesively secured with the cover support member  414  via a masking layer  420 . As shown in the enlarged view, an adhesive layer  440  may extend along a first surface  418 , a second surface  422 , and a third surface  424  of the rib  416 . With the adhesive layer  440  disposed across multiple surface of the rib  416 , an enhanced adhesive bond between the adhesive layer  440  and the cover support member  414  may withstand a load or force from multiple directions. For example, the cover support member  414 , having an adhesive secured to multiple surfaces of the rib  416 , may be able to withstand shearing forces in the direct denoted by a first arrow  442 , as well as tensional forces denoted by a second arrow  444 . Also, the rib  416  may be formed in a manner such an exterior surface of the protective cover  412  is co-planar, or approximately co-planar, with respect to an exterior surface of the cover support member  414 . 
       FIG. 11  illustrates a plan view of a cover support member  514  including a first attachment feature  518  and a second attachment feature  522  disposed in the cover support member  514 . The first attachment feature  518  and the second attachment feature  522  may be insert molded to the cover support member  514  during a molding operation of the cover support member  514 . Also, the first attachment feature  518  and the second attachment feature  522  may be used to secure the cover support member  514  with an enclosure (not shown).  FIG. 11  further shows the cover support member  514  having a first opening  524  and a second opening  526 . These openings may be referred to as wells, or adhesive wells, that allow for additional adhesive. 
       FIG. 12  illustrates a cross sectional view of an electronic device  500  having a cover support member  514  shown in  FIG. 11 . As shown, the first opening  524  of the cover support member  514  may allow a tool (not shown) to extend through the first opening  524  and adjust the cover support member  514  and/or the first attachment feature  518  that extends partially through the first opening  524 . Also, the first attachment feature  518  may couple with a first securing feature  528  in order to couple the cover support member  514  with an enclosure  502  of the electronic device  500 . 
       FIG. 13  illustrates a cross sectional view of the electronic device  500  shown in  FIG. 12 , showing a protective cover  512  secured with the cover support member  514  via a masking layer  520 . The first opening  524  (also shown in  FIG. 12 ) may be useful in instances when, for example, the number of layers of the masking layer  520  relatively fewer layers (the masking layer  520  shown as having three layers). For example, a bond line thickness of an adhesive layer  540  may be altered depending upon a change in the number of layers of the masking layer  520 . However, the first opening  524  may compensate for such a change. Further, the first opening  524  may allow the adhesive layer  540  to extend into the first opening  524 . When cured, the adhesive layer  540  may include an extension defined by the first opening  524 . This may allow for an adhesive bond (by the adhesive layer  540 ) that resists shear (or lateral) and tension forces applied to the electronic device  500 . 
       FIG. 14  illustrates a flowchart  600  showing a method for assembling an electronic device having a first part and a second part, in accordance with the described embodiments. The method may include providing one or more layers to the first part in order to provide a masking layer used to block light from passing between the first part and the second part. Each layer of masking layer may include pigments that define the color of the layer. Also, each layer may include a resin material that causes at least some of the pigments to bond with one another. Further, the resin material of one of the layers is used to provide an adhesive bond with the first part. Moreover, the ratio of resin to pigments of at least one layer may be greater than one or more remaining layers. While the increased resin may reduce the appearance of the layer, in terms of color, the remaining layers may include a ratio of pigments to resin that is higher than that of the layer to enhance the overall appearance, in terms of color, of the masking layer and provide an enhanced light block layer. 
     In step  602 , a first layer is disposed along the first part. The first layer may include a first composition having a first type pigment. The first layer may include an appearance that matches, in terms of color, that of a display frame of the electronic device. The first layer may be applied to the first part by a screen-printing operation. Also, the first composition may include both resin and the first type pigment (or several pigments of the first type). Further, the first composition may include an increase amount of resin, as compared to the remaining layers, in order to provide an enhanced adhesive bond with the first part. 
     In step  604 , a second layer is disposed on the first layer. The second layer may include a second composition having the first type pigment (or several pigments of the first type). Also, the second composition may be different from the first composition. For example, the second composition may include less resin that that of the first layer. However, the second composition may include a greater amount of the first type pigment as compared to the first layer. 
     The first layer and the second layer can combine to define a masking layer at an interface between the first part and the second part to prevent light transmission through the interface. Also, the masking layer may include several additional layers, some of which may include a composition similar to that of the second composition. Further, at least one of the layers may include a pigment different than the first type pigment such that the layer includes a gray appearance, or some appearance darker than that of the remaining layers. 
     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: 20160908
Publication Date: 20180703
Grant Date: 20180703
Priority Date: 20150908
Inventors: HOOTON, LEE E.
JARVIS, DANIEL W.
RAMMAH, MARWAN
SPRAGGS, IAN A.
MERZ, NICHOLAS G.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/0249", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0266", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/0266", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/0266", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1637", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1637", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 58190878