PATENT DOCUMENT

Publication Number: US-9644667-B2
Application Number: US-201313868037-A
Country: US
Kind Code: B2

Title: Floating fasteners

Abstract:
One or more floating fastener assemblies used to fasten components together are described. In some embodiments, the components are top and bottom portions of an enclosure of a computing device. Each floating fastener assembly can include a fastener having at least one surface that can engage with a surface of the enclosure to limit the rotation of the fastener during fastening. Each floating fastener can also include a clearance area for the fastener to “float” in a lateral direction with respect to the enclosure. Thus, when corresponding openings in the top and bottom portions of the enclosure are not exactly aligned, each fastener can shift laterally to allow screws to engage to fasten the top and bottom portions together.

Claims:
What is claimed is: 
     
       1. A floating fastener assembly for fastening first and second portions of an enclosure together, the first portion having an aperture and the second portion having a cavity, the floating fastener assembly comprising:
 a cylindrically shaped body characterized as having a longitudinal axis; 
 a flared portion at a first end of the cylindrically shaped body, the flared portion having a first edge that defines a first circular opening and a beveled interior surface that extends from the first edge to a second edge that defines a second circular opening that is smaller than the aperture, wherein the first circular opening is larger than the aperture; 
 a threaded portion of the cylindrically shaped body, the threaded portion having a threaded interior surface that extends from the second edge, the threaded interior surface capable of engaging a screw having a corresponding threaded surface, wherein during a screw insertion operation, the aperture and the beveled interior surface cooperate to align the screw with the longitudinal axis; and 
 a flange at a second end of the cylindrically shaped body, the flange extending outwardly from the longitudinal axis and having a size smaller than the cavity, the flange having a top surface and a stop surface, 
 wherein when the flange is within the cavity, movement in a longitudinal direction is limited by an engagement of the top surface with a first interior surface of the cavity and wherein rotational movement about the longitudinal axis is limited by an engagement of the stop surface with a second interior surface of the cavity. 
 
     
     
       2. The floating fastener assembly as recited in  claim 1 , wherein the screw is inserted through the aperture and threadably engages the threaded interior surface of the cylindrically shaped body to fasten the first portion to the second portion. 
     
     
       3. The floating fastener assembly as recited in  claim 2 , wherein the aperture has an opening taper and the screw has a corresponding screw taper configured such that when the first and second portions of the enclosure are fastened together, there is a consistent gap distance around a diameter of a screw head of the screw and the diameter of the aperture. 
     
     
       4. The floating fastener assembly as recited in  claim 2 , wherein the first portion is a top case of a base portion of a laptop computer and the second portion is a bottom case of the base portion of the laptop computer. 
     
     
       5. The floating fastener assembly as recited in  claim 1 , wherein the enclosure comprises multiple floating fastener assemblies arranged in multiple cavities. 
     
     
       6. The floating fastener assembly as recited in  claim 1 , wherein when the aperture and the threaded interior surface are not suitably aligned the floating fastener laterally shifts within a clearance area and within the cavity to allow the screw to properly seat within the threaded interior surface. 
     
     
       7. The floating fastener assembly as recited in  claim 1 , wherein the cavity is formed using at least one T-slot cutting tool. 
     
     
       8. An enclosure for a computing device having a lid portion fastened to a base portion, the base portion comprising a first portion having multiple enclosure openings and a second portion having multiple respective fastener cavities, and floating fasteners configured to be at least partially engaged within the multiple respective fastener cavities, each floating fastener comprising:
 a cylindrically shaped portion characterized as having a longitudinal axis; 
 a flared portion at a first end of the cylindrically shaped portion, the flared portion having a first edge that defines a first circular opening and a beveled interior surface that extends from the first edge to a second edge that defines a second circular opening that is smaller than a respective enclosure opening, wherein the first circular opening is larger than the respective enclosure opening; 
 a threaded portion having a threaded interior surface that extends from the second edge, the threaded interior surface capable of engaging a screw having a corresponding threaded surface, wherein during a screw insertion operation, the respective enclosure opening and the beveled interior surface cooperate to align the screw with the longitudinal axis; and 
 a flange at a second end of the cylindrically shaped portion, the flange extending outwardly from the longitudinal axis and having a size smaller than the respective fastener cavity, the flange having a top surface and a stop surface, 
 wherein when the flange of each floating fastener is within the respective fastener cavity, movement in a longitudinal direction is limited by an engagement of the top surface with an first interior surface of the respective fastener cavity and wherein rotational movement about the longitudinal axis is limited by an engagement of the stop surface with a second interior surface of the respective fastener cavity. 
 
     
     
       9. The enclosure as recited in  claim 8 , wherein the flared portion is configured to prevent the corresponding floating fastener from falling through a corresponding clearance opening that surrounds the cylindrical shaped portion of a respective floating fastener. 
     
     
       10. The enclosure as recited in  claim 8 , wherein when the enclosure openings and the corresponding second circular openings of the floating fasteners are not properly aligned, the floating fasteners transversely shift within corresponding clearance areas around the cylindrical shaped portion of a respective floating fastener and within the cavity to allow the screws to properly seat within the corresponding threaded interior surface. 
     
     
       11. The enclosure as recited in  claim 8 , wherein each of the enclosure openings has an opening taper and a corresponding screw taper configured such that when the lid portion and the base portion of the enclosure are fastened together, there is a consistent gap distance around screw heads of the screws and each of the corresponding diameters of the enclosure openings. 
     
     
       12. The enclosure as recited in  claim 8 , wherein the cavities are formed using a T-slot cutting tool. 
     
     
       13. An outer housing for a computing device, comprising:
 a bottom case adapted to contain a internal device components therein, the bottom case having fastener cavities; 
 a top case adapted to seal the internal device components within the outer housing the top case comprising fastening openings; and 
 floating fastener assemblies each collectively adapted to removably fasten the top case to the bottom case, wherein each of the floating fastener assemblies comprising:
 a fastener having a cylindrical portion having a threaded opening, wherein the threaded opening is configured to accept a screw; 
 a flared portion at a first end of the cylindrical portion, the flared portion having a internal beveled surface that extends between a first circular opening and a second circular opening that is smaller than the first circular opening and smaller than a respective fastening opening of the bottom case; and 
 a flange extending outward at a second end of the cylindrical portion, the flange having a stop surface, 
 wherein the fastener cavities have datum surfaces that are configured to engage with the stop surfaces to limit rotational movement of the fastener, wherein when the fastening opening is substantially aligned with the threaded opening of the fastener the screw can threadably engage with the threaded opening of the fastener, thereby fastening the top case and the bottom case together. 
 
 
     
     
       14. The outer housing as recited in  claim 13 , wherein the stop surfaces engage with datum surfaces so as to limit the movement of the fastener while the screw is threadably engaging the top and bottom cases. 
     
     
       15. The outer housing as recited in  claim 13 , wherein when the fastener opening and the threaded opening of the corresponding floating fasteners are not suitably aligned, the floating fasteners laterally shift within the cavity to allow the screws to properly seat within the threaded openings of the floating fasteners.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This U.S. Patent Application claims priority under 35 USC 119(e) to U.S. Provisional Patent Application No. 61/715,828 filed Oct. 18, 2012 entitled “Floating Fasteners” by Degner et al. which is incorporated by reference in its entirety for all purposes. 
    
    
     FIELD OF THE DESCRIBED EMBODIMENTS 
     The present invention relates generally to fastening components, and more particularly to fastening components that allow for looser tolerances in the mass production of consumer products. 
     BACKGROUND 
     There are a wide variety of ways to fasten device components together. One common fastening approach is to use screws, particularly where the ability to disassemble the device components is desirable. This can often mean that the components to be fastened together need to have threaded holes or other features in order to accommodate the screws. In many cases, each of the components or items to be fastened together can have holes that are sized and threaded for a particular screw. The screw can then be inserted into aligned corresponding holes in each component. 
     In mass produced devices such as portable electronic devices, such threaded holes are often built into an integrated portion of the component material itself. Multiple matching holes in corresponding components can be used to provide secure fastening of the components. For example, screws and holes can be strategically placed in portions of the outer housing components of a portable electronic device or other consumer product such that they can be fastened together in a secure fashion. However, the use multiple screws and screw holes can make it difficult to position the holes reliably such that they are align correctly with holes in a corresponding part. As such, the use of multiple screws and screw holes spaced apart on mating components often results in the need for relatively tight tolerances with respect to the size and location of the screw holes. Any introduction of relatively tight part tolerances in the context of mass production tends to increase costs, part rejection rates and production times. In addition, the use of threaded holes in a device component itself can result in the need to replace the entire device component if the threads become stripped, damaged or otherwise unusable in conjunction with a suitable fastening screw. 
     SUMMARY 
     It is an advantage of the present disclosure to provide parts and components that have looser tolerances with respect to their fastening aspects, and that still result in the functional and reliable fastening of those parts and components. This can be accomplished through the use of floating fastener assemblies for fastening of two or more parts together. 
     In various embodiments, a floating fastener assembly includes a fastener having a cylindrical portion and a flange, wherein the cylindrical portion has a threaded opening configured to accept a screw, and wherein the flange has a top surface and at least one stop surface. The floating faster assembly can also include a first portion of the enclosure that includes a clearance opening configured to accept the cylindrical portion of the fastener. The diameter of the clearance opening is preferably suitably larger than an outer diameter of the cylindrical portion of the fastener so as to provide a clearance area between the diameter of the clearance opening and the outer diameter of cylindrical portion of the fastener. The floating faster assembly can additionally include a cavity having an upper surface and at least one datum surface, wherein the upper surface is configured to engage with the top surface of the fastener and the at least one datum surface is configured to engage with the at least one stop surface of the fastener. The floating faster assembly can further include a second portion of the enclosure having an enclosure opening, wherein when the enclosure opening is substantially aligned with the threaded opening of the fastener, the screw can threadably engage the first and second portions of the enclosure. 
     In one particular embodiment, an enclosure for a computing device having a lid portion and a base portion is described. The base portion includes a number of floating fasteners, with each floating fastener having a cylindrical portion and a flange. Each cylindrical portion has a threaded opening configured to accept a screw, and each flange has a top surface and at least one stop surface. The base portion can also include a top case having a number of clearance openings configured to accept the floating fasteners, each clearance opening configured to accept the cylindrical portion of a corresponding floating fastener. In some cases, the diameter of each clearance opening is suitably larger than an outer diameter of the cylindrical portion of the corresponding floating fastener so as to provide a clearance area between the diameter of the clearance opening and the outer diameter of cylindrical portion. The top case can also include a number of cavities, each cavity having an upper surface and at least one datum surface, wherein each upper surface is configured to engage with the top surface of a corresponding floating fastener and each of datum surfaces is configured to engage with the stop surfaces of the corresponding floating fastener. The base portion can also include a bottom case configured to be removably fastened to the top case. The bottom case can have a number of enclosure openings, such that when the enclosure openings are aligned with the threaded openings of the plurality of floating fasteners, screws can threadably couple the top and bottom cases of the enclosure. 
     In some embodiments, an outer housing for a computing device is fastened using floating fasteners. The outer housing can include a bottom case adapted to contain a number of internal device components. The outer housing can also include a top case adapted to seal the internal device components within the outer housing. The outer housing can further include a number of floating fastener assemblies that are collectively adapted to removably fasten the top case to the bottom case. Each of the floating fastener assemblies can include a fastener having a flange and a threaded opening, wherein the threaded opening is configured to accept a screw and the flange has a plurality of stop surfaces. Each of the floating fastener assemblies can also include a clearance opening associated with the top case, wherein the clearance opening is configured to accept a fastener and a diameter of the clearance opening is suitably larger than an outer diameter of the fastener so as to provide a clearance area between the clearance opening and the fastener. Each of the floating fastener assemblies can also include a cavity having a number of datum surfaces, wherein the datum surfaces are configured to engage with the stop surfaces. Each of the floating fastener assemblies can also include an enclosure opening associated with the bottom case, wherein when the enclosure opening is substantially aligned with the threaded opening of the fastener, the screw can threadably engage with the threaded opening of the fastener, thereby fastening the top case and bottom case together. 
     Methods for fastening two portions of an enclosure together are also disclosed. In some embodiments, the method involves positioning a top case of the enclosure such that a number of floating fasteners of the top case can accept screws, wherein each floating fastener comprise a cylindrical portion and a flange. Each cylindrical portion can have a threaded opening configured to accept a screw. Each flange can have a top surface and stop surfaces. The top case can include a number of clearance openings, each clearance opening configured to accept the cylindrical portion of a corresponding floating fastener. The diameter of each of the clearance openings can be suitably larger than an outer diameter of the corresponding cylindrical portion so as to provide a clearance area between the diameter of the clearance opening and the outer diameter of cylindrical portion. The top case can also include a number of cavities, each cavity having an upper surface and datum surface. The upper surface can be configured to engage with the top surface of a corresponding fastener. The datum surfaces are configured to engage with the stop surfaces of the floating fastener. The method also includes placing a bottom case on the top case such that the enclosure openings of the bottom case are roughly centered with corresponding floating fasteners of the top case. The method further includes placing a number of screws in the enclosure openings of the bottom case and partially engaging the screws with the threaded openings of the floating fasteners of the top case. The method also includes adjusting the position of the bottom case to align with the top case using an alignment tool. Finally, the method includes tightening the screws to fully fasten the top and bottom cases. 
     Other apparatuses, methods, features and advantages of the invention will be or will become apparent to one with 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, be within the scope of the invention, and be protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  illustrates a front facing perspective view of an embodiment of a portable computing device in an open (lid) state; 
         FIG. 2  illustrates the portable computing device of  FIG. 1  in a closed (lid) state that shows rear cover and logo; 
         FIG. 3A  illustrates an external view of bottom case of the portable computing device of  FIGS. 1 and 2 ; 
         FIG. 3B  illustrates an internal view of the top case of the portable computing device of  FIGS. 1-3 ; 
         FIGS. 4A-4D  illustrate isometric and top-down views of an embodiment of a floating fastener arrangement; 
         FIGS. 5A and 5B  illustrate isometric and top-down views of different portions of another embodiment of a floating fastener arrangement; 
         FIGS. 6A-6C  illustrate isometric views of different portions of another embodiment of a floating fastener arrangement; 
         FIGS. 7A-7E  illustrate isometric and top-down views of different portions of another embodiment of a floating fastener arrangement; 
         FIGS. 8A-8C  illustrate a floating fastener arrangement at various stages of being formed in accordance with described embodiments; 
         FIGS. 9A-9C  illustrate close up cross-section views of a portion of an enclosure having an enclosure opening configured to accept screw; and 
         FIG. 10  illustrates a flowchart showing process steps for fastening two portions of an enclosure together using floating fasteners in accordance with described embodiments. 
         FIGS. 11A and 11B  illustrate views of a tool for flaring a floating fastener. 
     
    
    
     DETAILED DESCRIPTION OF SELECTED EMBODIMENTS 
     The following disclosure describes various embodiments of fastening devices. Certain details are set forth in the following description and Figures to provide a thorough understanding of various embodiments of the present technology. Moreover, various features, structures, and/or characteristics of the present technology can be combined in other suitable structures and environments. In other instances, well-known structures, materials, operations, and/or systems are not shown or described in detail in the following disclosure to avoid unnecessarily obscuring the description of the various embodiments of the technology. Those of ordinary skill in the art will recognize, however, that the present technology can be practiced without one or more of the details set forth herein, or with other structures, methods and components. 
     Representative applications of methods and apparatuses according to the present application are described in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     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 various embodiments relate to fasteners that can be used for the outer housing components of a computing device, such as any of the iMac® personal computer, MacBook® laptop computer or iPad® tablet computer manufactured by Apple Inc. of Cupertino, Calif. Although the subject computing device can be a portable computing device, including portable media players and cellular telephones, it can be readily appreciated that the various embodiments disclosed herein can also be used with larger personal computing devices, servers and the like. Furthermore, it can be readily understood that the fasteners can also be used in many other embodiments with other consumer products that are not computing devices. As such, the various inventive fastening screws, bolts, nuts and systems provided herein can be extended to a wide variety of other devices and applications, as can be readily appreciated in view of the entire disclosure. 
     Referring first to  FIG. 1 , one example of a personal computing device in the form of a laptop computer  100  is shown in front perspective view laptop in an open (lid) state. Laptop computer  102  can include base portion  102  formed of bottom case  104  fastened to top case  106 . Base portion  102  can be pivotally connected to lid portion  108  by way of clutch assembly  110  hidden from view by a cosmetic wall. Base portion  102  can include various internal components therein, such as processors, storage devices, busses, cards, power supplies, disk drives, I/O interfaces, modems, and the like. Top case  106  can be configured to accommodate various user input devices such as keyboard  114  and touchpad  116 . Lid portion  108  can include display  120  and rear cover  122  that can add a cosmetic finish to lid portion  108  and also provide structural support to at least display  120 . 
       FIG. 2  shows portable computing device  100  in a closed (lid) configuration that shows rear cover  122  and logo  202 . In one embodiment, logo  202  can be illuminated by light from display  120 . It should be noted that in the closed configuration, lid portion  108  and base portion  102  form what appears to be a uniform structure having a continuously varying and coherent shape that enhances both the look and feel of portable computing device  100 . 
     Continuing on,  FIG. 3A  shows an external view of bottom case  104  showing relative positioning of screws  320  used to secure bottom case  104  and top case  106  together. Screws  320  can pass through respective openings in bottom case  104  and threadably engage with threaded openings in top case  106 . In some embodiments, screws  320  are configured to be removably fastened to bottom case  104  and top case  106 . Support feet  302  can be formed of wear resistant and resilient material such as plastic. Also in view are multi-purpose front side sequentially placed vents  308  and  310  that can be used to provide a flow of outside air that can be used to cool internal components. In the described embodiment, vents  308  and  310  can be placed on an underside of top case  106  in order to hide the vents from view as well as obscure the view of an interior of laptop computer  100  from the outside. Floating fastening methods described herein can be used to secure some or all of screws  320 . 
       FIG. 3B  shows an interior view of top case  106  showing various internal structural features. For example, top case  106  can include palm rest zones  322  that can be expected to experience an external load applied by a user resting a palm or hand on top case  106  in the vicinity of palm rest zones  322 . Keyboard zone  324  can include keyboard support rib  326  that surrounds and defines a keyboard opening in keyboard zone  324 . Other structural zones can include touch pad zone  328 , side vents zone  330 , rear vent zone  332  and clutch bolt zone  334 . Top case  106  can include floating fasteners  336 - 340  for securing screws  320  (shown in  FIG. 3A ). As shown, floating fasteners  336 - 340  can be located at different portions of top case  106  and can be subject to different physical restraints. For example, corner fasteners  338  can be restricted by corner regions of the housing and front fasteners  336  can be restricted by the proximity to a touch pad to be positioned in touch pad zone  328 . A number of embodiments of floating fasteners will be described herein which can be used to secure different screws  320  at different locations that can be dependent partially upon the physical restraints of the fasteners. These embodiments will be described and illustrated with reference to  FIGS. 4-10  described below. 
     Turning now to  FIGS. 4A-4D , an embodiment of a floating fastener arrangement  400  is shown in perspective and top-down views. As shown, floating fastener arrangement  400  includes fastener  402 , which has a cylindrical portion  404  having a threaded opening  406 . Threaded opening  406  is configured to accept a screw (not shown). Fastener  402  also has flange  408  having a top surface  410  and stop surfaces  412  and  430 . Fastener  402  is positioned in a portion of enclosure  414 . Enclosure  414  can be, for example, top case  306  of  FIG. 3C . Enclosure  414  has a clearance opening  416 , which is configured to accept cylindrical portion  404  of fastener  402 . As shown, clearance opening  416  has a diameter  418  that is suitably larger than an outer diameter  422  of cylindrical portion  404  so as to provide a clearance area  420  between diameter  418  of clearance opening  416  and the outer diameter  422  of cylindrical portion  404  of fastener  402 . Clearance area  420  allows fastener  402  to move in X and Y directions relative to enclosure  414 . Thus, an opening of a corresponding enclosure portion is allowed a considerable amount of “float” or “play” during the alignment and coupling of the corresponding enclosure portions. Thus, when an enclosure opening is not suitably aligned with threaded opening  406 , fastener  402  can shift laterally within clearance area  420  to allow a screw to properly seat within threaded opening  406 . If more than one fastener is used to couple the corresponding enclosure portions, multiple floating fastener arrangements can be used. For example, referring back to  FIGS. 3A-3C , opening corresponding to screws  320  of bottom case  304  can each be allowed a certain amount of play when being fastened to top case  306 . This can permit looser location tolerances for the corresponding openings and provide greater ease of assembly. 
     Returning to  FIGS. 4A-4D , enclosure  414  has cavity  424  having upper surface  426  and datum surfaces  428  and  432 . During an assembly process when a screw is being screwed into threaded opening  406 , flange  408  of fastener  402  is situated within cavity  424 . Stop surface  412  can engage with datum surface  428  to limit rotation of fastener  402  in a clockwise direction. In addition, stop surface  430  can engage with datum surface  432  to limit rotation of fastener  402  in a counter clockwise direction. It should be noted that other surfaces of fastener  402  can engage with other surfaces of cavity  424  as fastener  402  is positioned within different regions of cavity  424  to limit rotation of fastener  402  during assembly. Additionally, upper surface  426  of cavity  424  can engage with top surface  410  of fastener  402 , thereby preventing fastener  402  from coming out of clearance opening  416  during assembly. Furthermore, fastener  402  can have a flared portion  434  at an end opposite to flange  408 , which can prevent fastener  402  from falling down through clearance opening  416 . In these ways, fastener  402  can be stabilized during assembly when a screw is being threaded into threaded opening  406 . 
     Moving now to  FIGS. 5A and 5B , another embodiment of a floating fastener arrangement  500  is shown. As shown, fastener  502  has a cylindrical portion  504  having a threaded opening  506 . Threaded opening  506  is configured to accept a screw (not shown). Fastener  502  also has flange  508  having a top surface  510  and stop surfaces  512  and  530 . Fastener  502  is positioned in a portion of enclosure  514 . Enclosure  514  can be, for example, top case  306  of  FIG. 3C . Enclosure  514  has a clearance opening  516 , which is configured to accept cylindrical portion  504  of fastener  502 . As shown, clearance opening  516  has a diameter  518  that is suitably larger than an outer diameter  522  of cylindrical portion  504  so as to provide a clearance area  520  between diameter  518  of clearance opening  516  and the outer diameter  522  of cylindrical portion  504  of fastener  502 . Clearance area  520  allows fastener  502  to move in a lateral direction relative to enclosure  514 . Thus, an opening of a corresponding enclosure portion is allowed a considerable amount of “float” or “play” during the alignment and coupling of the corresponding enclosure portions. Thus, when an enclosure opening is not suitably aligned with threaded opening  506 , fastener  502  can shift laterally within clearance area  520  to allow a screw to properly seat within threaded opening  506 . During assembly, stop surface  512  can engage with datum surface  528  to limit rotation of fastener  502  in a clockwise direction. In addition, stop surface  530  can engage with datum surface  532  to limit rotation of fastener  502  in a counter clockwise direction. It should be noted that other surfaces of fastener  502  can engage with other surfaces of the cavity of enclosure  514  as fastener  502  is positioned within different regions of the cavity to limit rotation of fastener  502  during assembly. Additionally, an upper surface of the cavity can engage with top surface  510  of fastener  502 , thereby preventing fastener  502  from coming out of clearance opening  516  during assembly. Furthermore, fastener  502  can have a flared portion  534  at an end opposite to flange  508 , which can prevent fastener  502  from falling down through clearance opening  516 . In these ways, fastener  502  can be stabilized during assembly when a screw is being threaded into threaded opening  506 . 
     Continuing on,  FIGS. 6A-6C  show another embodiment of a floating fastener arrangement  600 . As shown, floating fastener arrangement  600  includes fastener  602 , which has a cylindrical portion  604  having a threaded opening  606 . Threaded opening  606  is configured to accept a screw (not shown). Fastener  602  also has flange  608  having a top surface  610  and stop surfaces  612  and  630 . Fastener  602  is positioned in a portion of enclosure  614 . Enclosure  614  can be, for example, top case  306  of  FIG. 3C . Enclosure  614  has a clearance opening  616 , which is configured to accept cylindrical portion  604  of fastener  602 . As shown, clearance opening  616  has a diameter  618  that is suitably larger than an outer diameter  622  of cylindrical portion  604  so as to provide a clearance area  620  between diameter  618  of clearance opening  616  and the outer diameter  622  of cylindrical portion  604  of fastener  602 . Clearance area  620  allows fastener  602  to move in a lateral direction relative to enclosure  614 . Thus, an opening of a corresponding enclosure portion is allowed a considerable amount of “float” or “play” during the alignment and coupling of the corresponding enclosure portions. Thus, when an enclosure opening is not suitably aligned with threaded opening  606 , fastener  602  can shift laterally within clearance area  620  to allow a screw to properly seat within threaded opening  606 . If more than one fastener is used to couple the corresponding enclosure portions, multiple floating fastener arrangements can be used. 
     Enclosure  614  can have cavity  624  having upper surface  626  and datum surfaces  628  and  632 . During an assembly process when a screw is being screwed into threaded opening  606 , flange  608  of fastener  602  is situated within cavity  624 . Stop surface  612  can engage with datum surface  628  to limit rotation of fastener  602  in a clockwise direction. In addition, stop surface  630  can engage with datum surface  632  to limit rotation of fastener  602  in a counter clockwise direction. It should be noted that other surfaces of fastener  602  can engage with other surfaces of cavity  624  as fastener  602  is positioned within different regions of cavity  624  to limit rotation of fastener  602  during assembly. Additionally, upper surface  626  of cavity  624  can engage with top surface  610  of fastener  602 , thereby preventing fastener  602  from coming out of clearance opening  616  during assembly. Furthermore, fastener  602  can have a flared portion  634  at an end opposite to flange  608 , which can prevent fastener  602  from falling down through clearance opening  616 . In these ways, fastener  602  can be stabilized during assembly when a screw is being threaded into threaded opening  606 . 
     Moving to  FIGS. 7A and 7B , another embodiment of a floating fastener arrangement  700  is shown. As shown, floating fastener arrangement  700  includes fastener  702 , which has a cylindrical portion  704  having a threaded opening  706 . Threaded opening  706  is configured to accept a screw (not shown). Fastener  702  also has flange  708  having a top surface  710  and stop surfaces  712  and  730 . Fastener  702  is positioned in a portion of enclosure  714 . Enclosure  714  can be, for example, top case  306  of  FIG. 3C . Enclosure  714  has a clearance opening  716 , which is configured to accept cylindrical portion  704  of fastener  702 . As shown, clearance opening  716  has a diameter  718  that is suitably larger than an outer diameter  722  of cylindrical portion  704  so as to provide a clearance area  720  between diameter  718  of clearance opening  716  and the outer diameter  722  of cylindrical portion  704  of fastener  702 . Clearance area  720  allows fastener  702  to move in a lateral direction relative to enclosure  714 . Thus, an opening of a corresponding enclosure portion is allowed a considerable amount of “float” or “play” during the alignment and coupling of the corresponding enclosure portions. Thus, when an enclosure opening is not suitably aligned with threaded opening  706 , fastener  702  can shift laterally within clearance area  720  to allow a screw to properly seat within threaded opening  706 . If more than one fastener is used to couple the corresponding enclosure portions, multiple floating fastener arrangements can be used. 
     Enclosure  714  has cavity  724  having upper surface  726  and datum surfaces  728  and  732 . During an assembly process when a screw is being screwed into threaded opening  706 , flange  708  of fastener  702  is situated within cavity  724 . Stop surface  712  can engage with datum surface  728  to limit rotation of fastener  702  in a clockwise direction. In addition, stop surface  730  can engage with datum surface  732  to limit rotation of fastener  702  in a counter clockwise direction. It should be noted that other surfaces of fastener  702  can engage with other surfaces of cavity  724  as fastener  702  is positioned within different regions of cavity  724  to limit rotation of fastener  702  during assembly. Additionally, upper surface  726  of cavity  724  can engage with top surface  710  of fastener  702 , thereby preventing fastener  702  from coming out of clearance opening  716  during assembly. Furthermore, fastener  702  can have a flared portion  734  at an end opposite to flange  708 , which can prevent fastener  702  from falling down through clearance opening  716 . In these ways, fastener  702  can be stabilized during assembly when a screw is being threaded into threaded opening  706 . 
     As discussed above, the floating fasteners described herein can limit the rotation of the floating fasteners while screws are engaging with the floating fasteners.  FIGS. 7D and 7E  show top-down views of floating fastener arrangement  700  showing a limit of rotation of fastener  702 . At  FIG. 7D , fastener  702  is positioned such that stop surfaces  712  and  730  are not engaging with datum surfaces  728  and  732 . At  FIG. 7E , a force, such as a force from a screw being turning and engaging with threaded opening  706 , moves fastener  702  in a counterclockwise direction. As a result, stop surface  712  engages with datum surface  728 , thereby limiting rotation of fastener  702 . As shown, the rotation of fastener  702  results in a portion  750  of fastener  702  to protrude outside of cavity region  752 . The design of floating fastener arrangement  700  is such that portion  750  is minimized, thereby leaving more space for other components within enclosure  714 . In this way, the size or “footprint” of the floating fastener arrangement  700  is minimized so as to provide room for other components in the enclosure such as electronic components of a computer. 
     Continuing on,  FIGS. 8A-8C  show a floating fastener arrangement  800  at various stages of being formed in accordance with described embodiments. First, as shown in  FIG. 8A , a T-slot cutting tool  802  is used to form a first surface  840  within cavity  824  of enclosure  814 . Note that support member  844  protrudes from a corner of enclosure  814 . Support member  844  can also protrude from a non-corner side of enclosure  814 . Next, also shown in  FIG. 8A , a second T-slot cutting tool  804 , which is smaller than first T-slot cutting tool  802 , is used to form a second surface  842  within cavity  824  of enclosure  814 . It should be noted that in some embodiments a single type of T-slot cutting tool can be used to form the cavities of the floating fasteners described herein. Note that the T-slot cutting tools can be operated manually or by an automated machine. Next, as shown in  FIG. 8B , fastener  802  (having a similar shape and size as fastener  702  of  FIG. 7A ) is positioned to be inserted in to clearance opening  816  of enclosure  814 . Note that the top of fastener  812  has a straight cylindrical portion  804 . That is, a flared portion (such as flared portion  734  of  FIG. 7A ) has not yet been formed. This is so that fastener  802  can fit through clearance opening  816 . Note that first  840  and second  842  surfaces of within cavity  824  can be datum surfaces for stop surfaces of fastener  812  to engage with. Next, at  FIG. 8C , flared portion  834  is formed in fastener  802  so that fastener  802  does not fall through clearance opening  816 . Flared portion  834  can be formed, for example, by using a flare tool to push out the end of cylindrical portion  804 , resulting in a flared portion  834  having a larger outer diameter compared to clearance opening  816 . In one embodiment, the flare tool is a steel shaft having a threaded end configured to threadably engage with threaded opening  806 . The flare tool also has a tapered sleeve that can push out the top portion of cylindrical portion  804  as the threaded end of the flare tool is screwed into threaded opening  806 . Flared portion  834  can be formed either manually using a manual flare tool or automatically using an automated flare tool. Floating fastener arrangement  800  is now ready to accept a screw and couple with a corresponding enclosure portion. 
     In some embodiments described herein, the screws for fastening the top and bottom cases together can have features for providing a uniform look. To illustrate,  FIGS. 9A and 9B  show close up cross-section views of a portion  900  of top case  904  having an enclosure opening  914  configured to accept screw  902 . Screw  902  has a head  910 , cylindrical portion  908  and threaded portion  906  configured to threadably engage with a corresponding floating fastener (not shown). A diameter of enclosure opening  914  is larger than an outer diameter of the cylindrical portion  908  of screw  902 . At  FIG. 9A , screw  902  is positioned slightly to the right of the center  916  of enclosure opening  914 . If screw  902  is engaged with a corresponding floating fastener at in this configuration, the result is different distances  918  and  920  between head  910  and the edges of enclosure  904 . From a top level perspective, the screw  902  will appear skewed from the center  916  of enclosure opening  914 . Likewise, at  FIG. 9B , screw  902  is positioned slightly to the left of center  916  of enclosure opening  914 . If screw  902  is engaged with a corresponding floating fastener at in this configuration, the result is different distances  922  and  924  between head  910  and the edges of enclosure  904 . From a top-level perspective, the screw  902  will appear skewed from the center  916  of enclosure opening  914 . If a number of screws are used to secure the top and bottom cases together, each screw can be skewed a differing amount from their corresponding enclosure openings, resulting in an overall non-uniform appearance. 
     To address this issue, on some embodiments, the screws and corresponding enclosure openings can be tapered to provide an overall more uniform appearance. To illustrate,  FIG. 9C  show a close up portion  930  of top case  932  having enclosure opening  934  configured to accept screw  936 . Screw  936  has a head  938 , cylindrical portion  940  and threaded portion  942  configured to threadably engage with a corresponding floating fastener (not shown). A diameter of enclosure opening  914  is larger than an outer diameter of the cylindrical portion  940  of screw  936 . Enclosure opening  934  has a tapered region  948  and screw  936  has a corresponding screw taper  942 . As shown, this configuration allows screw  936  to be centered in relation to center  946  of enclosure opening  934 . If screw  936  is engaged with a corresponding floating fastener in this configuration, the distance  944  between head  938  and the edges of enclosure  932  is substantially the same. That is, there is a consistent gap distance  944  around a diameter of a head  938  of screw  936  and the diameter of enclosure opening  934 . If a number of screws are used to secure the top and bottom cases together, each screw can be centered with respect to their corresponding enclosure openings, resulting in an overall uniform appearance. 
     Moving on,  FIG. 10  is a flowchart  1000  showing process steps for fastening two portions of an enclosure together using floating fasteners in accordance with described embodiments. At  1002 , a top case of the enclosure is positioned such that floating fasteners positioned thereon can accept screws. For example,  FIG. 3B  shows interior portion of top case  106  positioned such that floating fasteners  336 - 340  can accept screws. In some embodiments, the top case is secured to a fixture to prevent movement of the top case during the fastening procedure. At  1004 , a bottom case of the enclosure is placed on top of the top case. In addition, the enclosure openings of the bottom case are roughly centered with the threaded openings of the corresponding floating fasteners of the top case. For example,  FIG. 3A  shows screws  320  positioned in enclosure openings of bottom case  104  that can be roughly centered with the threaded openings of corresponding floating fasteners  336 - 340  of  FIG. 3B  during the fastening procedure. At  1006 , screws are placed in the enclosure openings of the bottom case and partially engaged with the threaded openings of the floating fasteners of the top case. As described above, if the enclosure openings and the threaded openings of the floating fasteners are not suitably aligned, the floating fasteners can laterally shift within the clearance openings to allow the screws to be properly seat within the threaded openings in the floating fasteners. Note that when the screws are partially engaged, the floating fasteners are still allowed to laterally shift within the clearance openings. At  1008 , the position of the bottom case is more precisely aligned with the top case. Note that the position of the bottom case can be moved laterally with respect to the top case even though the screws are partially engaged with the floating fasteners. In some embodiments, an alignment tool, such as a charge-coupled device (CCD) camera alignment tool, is used to align the edges of the top and bottom cases. In this way, once the top and bottom cases are completely fastened, the interface between the top and bottom case enclosure can have substantially no step resulting in a substantially flush interface. Other alignment tools, such as physical alignment members such a side and corner stops or laser alignment tools, can be used. At  1010 , the screws are tightened to fully fasten the top and bottom cases together. 
       FIG. 11A  is a view of one embodiment of a tool for forming a flare on a floating fastener. Oftentimes a floating fastener can include a flared portion such as shown in  FIGS. 6A-6C  or  FIGS. 7A-7E . In some embodiments, the flared portion can be formed after the floating fastener is inserted into top case  106 . The flaring tool  1100  can be used to engage the floating fastener with tip  1105  and the floating fastener can be flared with conical section  1110 .  FIG. 11B  shows a cross sectional view  1120  of another embodiment of a floating fastener flare forming tool. 
     Although the foregoing invention has been described in detail by way of illustration and example for purposes of clarity and understanding, it will be recognized that the above described invention may be embodied in numerous other specific variations and embodiments without departing from the spirit or essential characteristics of the invention. Certain changes and modifications may be practiced, and it is understood that the invention is not to be limited by the foregoing details, but rather is to be defined by the scope of the appended claims.

Metadata:
Filing Date: 20130422
Publication Date: 20170509
Grant Date: 20170509
Priority Date: 20121018
Inventors: FARAHANI HOUTAN R.
DEGNER BRETT W.
LEGGETT WILLIAM F.
SILVANTO MIKAEL M.
ANDRE BARTLEY K.
Assignee: APPLE INC
CPC Classifications: [{"code": "F16B5/0664", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1633", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1633", "inventive": true, "first": false, "tree": "[]"}, {"code": "F16B5/0642", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49948", "inventive": false, "first": false, "tree": "[]"}, {"code": "F16B5/0642", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": false, "tree": "[]"}, {"code": "F16B39/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": true, "tree": "[]"}, {"code": "F16B5/0664", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49948", "inventive": false, "first": false, "tree": "[]"}, {"code": "F16B5/0664", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49948", "inventive": false, "first": false, "tree": "[]"}, {"code": "F16B39/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "F16B5/0642", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1633", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 50484009