PATENT DOCUMENT

Publication Number: US-10021480-B2
Application Number: US-201414495777-A
Country: US
Kind Code: B2

Title: Integrated speakers

Abstract:
An enclosure for an electronic device is enclosed. The enclosure includes rib structures configured to improve structural support to prevent damage and to dissipate vibration throughout the enclosure. The rib structure can receive a speaker module and a cap member. The rib structure and the speaker module can combine to form a three-dimensional volume allowing the speaker module in which the speaker module may project sound, thereby enhancing acoustic performance. Also, the cap member may be adhesively attached to the rib structure to provide additional structural support against vibration and abuse caused by load forces associated with a drop event.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 an enclosure comprising:
 a plurality of ribs comprising:
 a first rib structure engaged with a sidewall of the enclosure and at least partially defining a first chamber; 
 a second rib structure at least partially defining a second chamber different from the first chamber; and 
 a shared rib defining a portion of both the first chamber and the second chamber; 
 
 
 an audio device comprising a cover in contact with and forming an acoustic seal over a top of the first rib structure, the audio device defining:
 a first opening configured to project first sound waves in a first direction towards an area of the sidewall where a speaker opening is located; and 
 a second opening configured to project second sound waves in a second direction opposite the first direction and towards the shared rib; and 
 
 a cap member covering the second rib structure. 
 
     
     
       2. The electronic device as recited in  claim 1 , further comprising an underpass through the first rib structure, wherein the underpass opens the first chamber to the second chamber. 
     
     
       3. The electronic device as recited in  claim 2 , wherein when the audio device is positioned within the first chamber, the audio device is capable of emitting sound through the underpass. 
     
     
       4. The electronic device as recited in  claim 1 , further comprising means for securing the audio device to the first rib structure, and means for securing the cap member to the second rib structure. 
     
     
       5. The electronic device as recited in  claim 4 , wherein the means for securing the cap member to the second rib structure comprises a flange receiving the cap member and an adhesive securing the cap member to the flange. 
     
     
       6. The electronic device as recited in  claim 5 , wherein the cap member comprises a composite material and defines a plurality of protrusions adhesively secured to the enclosure. 
     
     
       7. The electronic device as recited in  claim 5 , further comprising:
 an additional plurality of ribs comprising:
 a third rib structure engaged with the sidewall of the enclosure and at least partially defining a third audio chamber; and 
 a fourth rib structure at least partially defining a fourth chamber different from the third chamber;
 and 
 
 an additional shared rib defining a portion of both the third chamber and the fourth chamber; 
 
 an additional audio device comprising an additional cover in contact with and forming an additional acoustic seal over a top of the third rib structure; and
 a cap member covering the fourth rib structure. 
 
 
     
     
       8. The electronic device of  claim 1 , wherein the cap member forms an acoustic seal over a top of the second chamber. 
     
     
       9. The electronic device of  claim 1 , wherein a top of the first rib structure and a top of the second rib structure together define a single plane. 
     
     
       10. An electronic device, comprising:
 an enclosure, comprising:
 a plurality of sidewalls integrally formed around an outer peripheral portion of the enclosure and comprising a sidewall having an aperture therethrough; 
 
 a first plurality of ribs integrally formed on a rear portion of the enclosure and including:
 a first rib structure engaged with the sidewall of the enclosure and at least partially defining a first chamber; 
 a second rib structure at least partially defining a second chamber different from the first chamber; and 
 a shared rib defining a portion of both the first chamber and the second chamber and positioned opposite the aperture in the sidewall; 
 
 a speaker module comprising:
 a cover in contact with and forming an acoustic seal over a top of the first rib structure; 
 a first wall defining a first opening that faces the aperture in the sidewall; and 
 a second wall defining a second opening that faces the shared rib; and 
 
 a cap member in contact with and forming an acoustic seal over a top of the second rib structure. 
 
     
     
       11. The electronic device as recited in  claim 10 , wherein the cap member is adhesively secured to the second rib structure. 
     
     
       12. The electronic device as recited in  claim 10 , further comprising an underpass in the shared rib, the first underpass opening to the first chamber and the second chamber. 
     
     
       13. The electronic device as recited in  claim 12 , wherein the speaker module emits sound through the aperture and the underpass. 
     
     
       14. The electronic device of  claim 10 , wherein a top of the first rib structure and a top of the second rib structure together define a single plane. 
     
     
       15. The electronic device of  claim 10 , wherein the first wall and the second wall are substantially parallel to one another. 
     
     
       16. The electronic device of  claim 10 , wherein:
 the first wall is substantially parallel to the sidewall; and 
 the second wall is substantially parallel to the shared rib. 
 
     
     
       17. A method comprising:
 forming an enclosure, comprising:
 removing a portion of an aluminum substrate to form a plurality of sidewalls, the plurality of sidewalls having a first sidewall; 
 removing a portion of the plurality of sidewalls to define a location that receives a cover glass; 
 removing a portion of the aluminum substrate to define a continuous rib structure defining:
 a first rib structure at least partially defining a first chamber; 
 a second rib structure at least partially defining a second chamber; and 
 a third rib structure defining a portion of each of the first and the second chambers, wherein the first, second, and third rib structures each extend substantially a same height above a back surface of the enclosure; 
 
 forming an aperture in the first sidewall, the aperture opening into the first chamber; and 
 removing a portion of the third rib structure to define an underpass in the third rib structure while maintaining the first, second, and third rib structures at the same height above the back surface of the enclosure; 
 
 attaching an audio device to the first rib structure such that a first opening in the audio device faces the aperture and a second opening in the audio device faces the third rib structure; and 
 attaching a cap member to the second rib structure to acoustically seal the second chamber. 
 
     
     
       18. The method as recited in  claim 17 , further comprising:
 removing a portion of the second rib structure to define a flange member; and 
 securing the cap member to the flange member using an adhesive. 
 
     
     
       19. The method as recited in  claim 17 , wherein the aperture allows sound from the audio device to escape the enclosure. 
     
     
       20. The method as recited in  claim 17 , wherein attaching the audio device to the first rib structure acoustically seals the first chamber.

Description:
FIELD 
     The described embodiments relate generally to an enclosure of an electronic device. In particular, the present embodiments relate to structural features which enhance the strength and rigidity of the enclosure as well as provide acoustic enhancements. 
     BACKGROUND 
     Enclosures provide structural support for electronic devices. Generally, enclosures are made from stiff materials to protect against damage to internal components (e.g., processors) as well as external components (e.g., cover glass). Damage to components may occur from several events, such as dropping the device. In order to maintain the structural rigidity of relatively large electronic devices, the enclosures may be formed with greater thickness. 
     However, enclosures having greater thickness may offer less internal space for components. Further, additional thickness corresponds to additional material which may increases the cost of the electronic device. Additional thickness also corresponds to additional weight of the device which is generally undesirable, especially portable electronic devices. On the other hand, electronic devices with relatively thin enclosures may feel flimsy to a user and offer less structural support and less resistance to damage. Further, a speaker module within the electronic device may project sound at a frequency equal to the resonant frequency of the material of the enclosure, causing unwanted vibration throughout the enclosure. 
     SUMMARY 
     In one aspect, an enclosure for an electronic device is described. The enclosure may include a plurality of ribs defining a rib structure extending along a rear portion of the enclosure. In some embodiments, the plurality of ribs includes a first portion engaged with a sidewall of the enclosure. In some embodiments, the first portion receives an audio device. The plurality of ribs may further include a second portion different from the first portion. In some embodiments, the second portion receives a cap member. Also, in some embodiments, the plurality of ribs includes a first rib that is shared by the first portion and the second portion. 
     In another aspect, an enclosure for an electronic device is described. The enclosure may include several sidewalls integrally formed around an outer peripheral portion of the enclosure. The several sidewalls may include a first wall having a first aperture and a second aperture. The enclosure may further include a first plurality of ribs integrally formed on a rear portion of the enclosure to define a first portion and a second portion. In some embodiments, the first portion is adapted to receive a first component on a first flange member positioned within the first portion. Also, in some embodiments, the second portion is adapted to receive a second component on a second flange member positioned within the second portion. The enclosure may further include a second plurality of ribs different from the first plurality of ribs. In some embodiments, the second plurality of ribs is integrally formed on the rear portion of the enclosure to define a third portion and a fourth portion. In some embodiments, the third portion is adapted to receive a third component on a third flange member positioned within the third portion. Also, in some embodiments, the fourth portion is adapted to receive a fourth component on a fourth flange member positioned within the fourth portion. In some embodiments, both the first plurality of ribs and the second plurality of ribs engage the first wall. In some embodiments, the first aperture opens into the first portion. In some embodiments, the second aperture opens into the third portion. 
     In another aspect, a method for forming an enclosure of an electronic device is described. The method may include removing a portion of an aluminum substrate to form a plurality of sidewalls; the plurality of sidewalls may have a first sidewall. The method may further include removing a portion of the plurality of sidewalls to define a location that receives a cover glass. The method may further include removing a portion of the aluminum substrate to define a rib structure having a first rib and a second rib. In some embodiments, the first rib and second rib are adapted to receive an audio device and a cap member. In some embodiments, the first rib and the second rib both engage the first sidewall. The method may further include removing a first aperture in the first sidewall; first aperture may open into a location between the first rib and the second rib. 
     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 electronic device in accordance with the described embodiments; 
         FIG. 2  illustrates the electronic device shown in  FIG. 1  with the cover glass, display panel, and internal components removed, in accordance with the described embodiments; 
         FIG. 3  illustrates an isometric view of an enlarged view of the enclosure in  FIG. 2  showing features of a rib structure, in accordance with the described embodiments; 
         FIG. 4  illustrates an isometric view of an enlarged portion of the enclosure in  FIG. 2  showing features another rib structure, in accordance with the described embodiments; 
         FIG. 5  illustrates a top view of a rib structure receiving a cap member having several protrusions, in accordance with the described embodiments; 
         FIG. 6  illustrates a cross sectional view of the rib structure and the cap member shown in  FIG. 5  and taken along the line  6 - 6  to show cap member adhesively secured to rib structure, in accordance with the described embodiments; 
         FIG. 7  illustrates a top view of an alternate embodiment of a rib structure having diagonal ribs within the rib structure; 
         FIG. 8  illustrates a top view of an embodiment of a rib structure bosses within the rib structure, the bosses extending from a rear portion of the enclosure; 
         FIG. 9  illustrates a cross sectional view of the rib structure shown in  FIG. 8  and taken along the line  9 - 9  to show cap member adhesively secured to rib structure, in accordance with the described embodiments; 
         FIG. 10  illustrates an embodiment of a cap member having protrusions positioned in various locations of the cap member; 
         FIG. 11  illustrates an embodiment of a cap member having protrusions of various shapes and sizes, and positioned in various locations of the cap member; 
         FIG. 12  illustrates an enlarged portion of an embodiment of a cap member having fibers aligned in an orthotropic configuration; 
         FIG. 13  illustrates an enlarged portion of an alternate embodiment of a cap member having fibers aligned in a different orthotropic configuration; 
         FIG. 14  illustrates an enlarged portion of an embodiment of a cap member having fibers aligned in a diagonal configuration; 
         FIG. 15  illustrates a portion of an electronic device having an enclosure with a first rub structure and a second rib structure, both of which integrally formed to a rear portion and first sidewall of the enclosure, in accordance with the described embodiments; 
         FIG. 16  illustrates an isometric view of the area denoted in  FIG. 15  as Section A, showing a third rib portion and a fourth rib portion integrally formed with a rear portion and a sidewall of an enclosure, in accordance with the described embodiments; 
         FIG. 17  illustrates a top view of an embodiment of a rib structure having an acoustic foam positioned within the rib structure; 
         FIG. 18  illustrates a top view of an embodiment of a rib structure having a component positioned within the rib structure; and 
         FIG. 19  illustrates a flowchart showing a method for forming an enclosure of an electronic device. 
     
    
    
     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 enclosure of an electronic device. The enclosure may be formed from a unitary substrate of a metal, such as aluminum, with several portions of the substrate removed by machining the substrate. Removal means may include a computer numeric control (“CNC”) machine and/or a water jet. The remaining portions of the substrate after the removal process may be referred to as “integrally formed” with the enclosure. Alternatively, the enclosure may be formed by additive manufacturing processes. For instance, a printer, such as a three-dimensional printer, capable of printing multiple, stacked layers of resin material may be used to print the enclosure with integrally formed ribs. 
     Some portions of the substrate may be removed to form rib structures which may serve several functions. For example, the rib structures may extend along a rear portion of the enclosure and improve the structural rigidity of the enclosure, making the enclosure more resistant to bending. Also, the rib structures may be integrally formed with a sidewall of the enclosure. This allows the rear portion to include an increased size (e.g., length and/or width) while maintaining a relatively small thickness, such as 1-2 millimeters (“mm”) or less. These integrally formed rib structure provides resistance to bending and/or twisting of the enclosure which may prevent damage to the electronic device or some of its components. Also, the rib structure provides additional resistance against drop events, such as when a user drops the electronic drive. For instance, the load, or force, incurred by the electronic device during a drop event may be distributed by the rib structure throughout the enclosure rather than a localized area associated with a location in which the electronic device collides with a surface. 
     The rib structure may also be adapted to, or designed to, receive an audio device (e.g., speaker module) and a cap member. The cap member may be formed from a composite material that includes, for example, carbon fiber. The composite material may include other forms of fibers. In either event, the fibers may be aligned with a critical load path, defined as the direction or orientation of a load, or force, received by the electronic device during a drop event. The cap member may be adhesively secured to the rib structure, thereby providing additional resistance against drop events. To provide additional support, the cap member may include one or more protrusions adhesively secured to the rear portion of the enclosure. Adhesively securing the cap member, including protrusions, to the enclosure also provides added stiffening strength. The cap member may not only absorb some of the force received from the drop event, but also stabilize the rib structure by preventing or limiting movement of the rib structures during the drop event. Also, the cap member and the rib structure (and in some cases, the audio device) may combine to form an enclosed volume or region of air which serves as a “back volume” for the audio device, allowing the audio device to project some sound through the back volume, thereby enhancing the audio quality of the electronic device. In instances where an electronic device includes multiple audio devices, there may be an associated back volume configured to allow the multiple audio devices to emit sound from the electronic device having the same sound levels (e.g., in decibels). As a result, the user may experience a consistent sound from the electronic device. 
     In some cases, the enclosure may include a material having an associated resonant frequency, or resonant frequencies. Sound emitted from the audio device at the resonant frequency may cause or drive relatively high vibrations through the enclosure in an unwanted manner. However, the back volume described above may be designed to reduce or dampen these frequencies emitted by the audio device. For instance, the enclosed volume of air may allow the sound energy to dissipate before extending throughout the enclosure. Further, the composite material forming the cap member may absorb sound energy. In this manner, the audio device can emit sound having a range of frequencies, including one or more resonant frequencies of the material of the enclosure, without causing unwanted vibration due to a resonant moment associated with a period in which the audio device emits sound at the resonant frequency. Further, some electronic devices may include several audio devices. In this case, the enclosure may include additional rib structures and cap members corresponding to the number of audio devices. The design and layout of each rib structure coupled with the design of each cap member and protrusions thereof create an electronic device having multiple audio devices that drive sound at approximately the same sound levels, creating electronic device with a consistent sound. 
     These and other embodiments are discussed below with reference to  FIGS. 1-19 . 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 embodiment of an electronic device  100 . In some embodiments, electronic device  100  is a tablet computing device, such as an iPad® from Apple Inc., of Cupertino, Calif. In other embodiments, electronic device  100  is mobile communications device, such as a smartphone. Electronic device  100  includes enclosure  102  that receives cover glass  104 . In some embodiments, enclosure  102  is made from a metal, such as aluminum. Display panel  106  may be positioned between enclosure  102  and cover glass  104 , and also be capable of driving visual display content visible through cover glass  104 . 
       FIG. 2  illustrates a top view of electronic device  100  with the cover glass and display panel removed. Also, for purposes of clarity and simplicity, several internal components (e.g., processors, batteries, memory device, etc.) have been removed to show rear portion  108  and sidewalls  110 . It should be understood that rear portion  108  is only intended for purposes of description and is not intended to demarcate a precise location of enclosure  102 . Rear portion  108  may generally be associated with a portion of enclosure  102  within sidewalls  110 . Also, sidewalls  110  generally represent a four-side sidewall structure on the outer peripheral portion of enclosure  102 . 
     Enclosure  102  includes several rib structures positioned on rear portion  108 . Each of the rib structures is capable of receiving both an audio device and a cap member. For example, first rib structure  112  includes first audio device  114  and first cap member  116 . In some embodiments, first rib structure  112  is adhesively secured to enclosure  102 . In the embodiment shown in  FIG. 2 , first rib structure  112  is formed from a machining process (e.g., CNC tool, water jet machine) configured to remove material from enclosure  102  to form first rib structure  112 . In other words, first rib structure  112  is integrally formed with enclosure  102  and accordingly, made from the same material as enclosure  102 . First rib structure  112  may also be referred to as several ribs integrally formed to define a multi-sided structure. First rib structure  112  may provide structural support as well as resistance to bending and/or twisting of enclosure  102 , particularly in instances where rear portion  108  is relatively thin (e.g., approximately 1 mm). 
     Also, first audio device  114  is positioned within first rib structure  112  and electrically connected to an internal component, such as an audio processor (not shown). In some embodiments, first audio device  114  is a speaker module having a passive radiator and capable of emitting sound. First audio device  114  may be configured to drive sound from electronic device  100  to be heard by a user. Sounds may derive from, for example, a ring tone, an audio file, or a video file, all of which may be stored in a memory device (not shown) within electronic device  100 . 
     First cap member  116  is also positioned on first rib structure  112  and generally positioned proximate to first audio device  114 . In some embodiments, first cap member  116  is adhesively secured to a portion of first rib structure  112 . Also, in some embodiments, first cap member  116  is made from a metallic material or a metal alloy. In the embodiment shown in  FIG. 2 , first cap member  116  is a composite structure made from materials including carbon fiber. Generally, first cap member  116  may be made from any material preferably having a relatively low weight and relatively high specific stiffness. Further, cap member  116  may generally include any material or materials having high specific stiffness and good damping characteristics, including but not limited to homogeneous alloys or highly orthotropic composite materials. This allows cap member  116  to contribute to the rigidity of enclosure  102  while also reducing some acoustic effects associated with the audio devices. Also, first cap member  116  may be cut from a large sheet of the composite material in a manner that fits within a rib structure, such as first rib structure  112 . Also, in some embodiments, first cap member  116  includes several protrusions  118 , which include first protrusion  120 , extending from surface of first cap member  116  to rear portion  108 . In some embodiments, protrusions  118  are adhesively secured to rear portion  108 , which will be shown later. First cap member  116  and first rib structure  112  combine to form a semi-hollow enclosed volume or region of air, also referred to as a back volume, through which first audio device  114  may project sounds waves in order to enhance or increase acoustic performance. This will be shown and discussed later in further detail. 
       FIG. 3  illustrates an exploded view of an enlarged portion of enclosure  102  showing first rib structure  112  receiving first audio device  114  in a first portion of first rib structure  112  and first cap member  116  in a second portion. First cap member  116  and protrusions  118  may be adhesively secured to first rib structure  112 . While each of protrusions  118  are adhesively secured to rear portion  108  of enclosure  102 , first cap member  116  may be adhesively secured to flange member  202  within first rib structure  112 . An enlarged view showing a portion of first rib structure  112  show flange  202  generally horizontal and capable of receiving adhesive  204 . Flange member  202  may be formed during the material removal process previously described for forming first rib structure  112 . First rib structure  112  may include length or thickness  205  approximately in the range of 0.8 to 3 mm. Also, flange  202  may have a length  206  approximately in the range of 1-3 mm, and preferably at least 1.5 mm to provide adhesive  204  with a sufficient area as well as provide a sufficient area for first cap member  116  to adhesively secure to first rib structure  112 . Flange  202  may include a substantially uniform thickness  206  through first rib structure  112 . Also, adhesive  204  may be selected from methacrylate, exopy, or pressure sensitive adhesive (“PSA”). In the embodiment shown in  FIG. 3 , adhesive  204  is urethane. 
     First audio device  114  may be secured to first rib structure  112  in several ways. For example, in some embodiments, first audio device  114  includes a bead made from a compressible material that fits into a mechanical clip positioned within first rib structure  112 . In the embodiment shown in  FIG. 3 , first audio device  114  is adhesively secured to first rib structure  112  in a manner similar to first cap member  116 , i.e., by using a flange member  208  within first rib structure  112  to adhesively secure to flange member  210  of first audio device  114 . Also, in order for sound to escape electronic device  100 , sidewall  110  may include an apertures  224 , commonly referred to as a speaker grill, allowing sound to pass from first opening  212  of first audio device  114 . It will be appreciated that other configurations of cap member and audio devices (e.g., shown in  FIG. 2 ) may include substantially all of the features associated with first rib structure  112 , such as securing means of an audio device and a cap member to rib structures. 
     When the audio devices and cap members are secured to the rib structures, an acoustic seal may be formed between individual rib structures and their respective cap member. For example  FIG. 4  illustrates an enlarged view of a portion of enclosure  102  showing fourth cap member  146  (shown in  FIG. 2 ) adhesively secured to fourth rib structure  142 . For purposes of illustration, a portion of fourth cap member  146  is not shown in order to illustrate an additional feature. Back volume  214  may be defined as a space or region enclosed between fourth rib structure  142  and fourth cap member  146  (including protrusions  148 ). In this regard, when fourth audio device  144  is secured to fourth rib structure  142 , an acoustic seal may be formed and air within back volume  214  may be substantially trapped. As such, air will generally not escape when fourth audio device  144  projects sound into back volume  214 . Also, fourth rib structure  142  may include first rib  158 , which includes a portion of material removed to define an underpass  216 . In other embodiments, fourth rib structure includes underpass  216  within second rib  162 . Still, in other embodiments, fourth rib structure  142  includes an underpass within both first rib  158  and second rib  162 . Generally, underpass  216  may formed in a location of fourth rib structure  142  such that underpass  216  opens to a first portion and a second portion of fourth rib structure  142  share a rib, where the first portion and the second portion receive fourth audio device  144  and fourth cap member  146 , respectively. In some embodiments, underpass  216  is formed by a removal tool such as a T-cutter (not shown). In this manner, when fourth audio device  144  is secured to fourth rib structure  142 , first audio device  144  may project sound waves, via second opening  218 , into back volume  214 , via underpass  216 , in order to enhance or increase acoustic performance. 
     Also, because the acoustic seal may substantially trap air within the back volumes, issues may arise when an electronic device is subjected to different altitudes. In instances when the electronic device is carried on a commuter jet plane, which may reach altitudes of 30,000 feet or more, air pressure within back volume  214  may substantially decrease, causing fourth cap member  146  break the adhesive bond between with rib structure  142  and at least partially decouple. In order to prevent this, in some embodiments, fourth cap member  146  includes vent  220 . Vent  220  may be any opening positioned anywhere on fourth cap member  146 , and in some cases between protrusions  148 , allowing some air movement into and out of back volume  214 . Vent  220  includes a diameter approximately in the range of 0.2 to 0.5 mm. Generally, vent  220  includes a diameter small enough not to allow a substantial amount of air to pass into and out of during periods of decreased and increased elevation, respectively. It will be appreciated that a vent may be formed in a similar manner to other cap members within the electronic device. 
       FIG. 4  further shows rear portion  108  having thickness  168 . Thickness  168  may be approximately in the range of 0.4 to 2 mm. Also, rear portion  108  may include a substantially uniform thickness  168 . In order to receive a cover glass (shown in  FIG. 1 ), in some embodiments, enclosure  102  includes surface  172  formed form a material removal process previously described. Surface  172  may extend around enclosure  102  in a manner similar to that of side wall  110 , and is designed to receive the cover glass. 
     Referring again to  FIG. 2 , in some cases, first audio device  114  may project sound waves into an associated back volume (previously described) at a frequency equal to a resonance frequency of the material forming enclosure  102 . As a result, enclosure  102 , including rear portion  108 , may respond by vibrating at the resonant frequency which includes an amplitude greater than that of the amplitude associated with the frequency of sound waves produced by first audio device  114 . In some cases, this vibration can be felt by a user holding electronic device  100 , creating an undesirable user experience. To dampen, or reduce, the effects of the resonant frequency vibrating enclosure  102 , first rib structure  112 , first cap member  116 , and protrusions  118  may combine to absorb some of the energy associated with the sound waves causing the resonant frequency. For instance, a back volume enclosed by rear portion  108 , first rib structure  112 , first cap member  116 , and protrusion  118  may receive the sound waves to pass and allow the energy associated with the sound waves to dissipate when contacting the aforementioned structures. Also, first cap member  116  may further dissipate the energy, particularly in instances when first cap member  116  is formed from fibers. For example, the sound waves may be dissipated by traversing between the fibers within first cap member  116 . These features allow enclosure  102  to acoustically decouple from portions of enclosure  102  associated with first audio device  114 , such as a portion contained by first rib structure  112 . It should be understood that these features may be associated with other audio devices within enclosure  102 . In this manner, the user experience may be improved as resonance frequencies, or resonant moments, produced by audio devices are generally unnoticed by the user. 
     Electronic device  100  may include additional rib structures also capable of receiving audio devices and cap members. In some embodiments, electronic device  100  includes a pair of rib structures, audio devices, and cap members. In other embodiments, electronic device  100  includes three rib structures, audio devices, and cap members. In the embodiment shown in  FIG. 2 , electronic device  100  includes four rib structures, audio devices, and cap members. In addition to the aforementioned rib structure, audio device, and cap member, electronic device  100  further includes second rib structure  122 , third rib structure  132 , and fourth rib structure  142  that receiving second audio device  124 , third audio device  134 , and fourth audio device  144 , respectively. Also, second rib structure  122 , third rib structure  132 , and fourth rib structure  142  receive second cap member  126 , third cap member  136 , and fourth cap member  146 , respectively. Also, shown in  FIG. 2 , second cap member  126  includes protrusions  128 , third cap member  136  includes protrusions  138 , and fourth cap member  146  includes protrusions  148 . These structures may include any feature similar to those previously described. For example, third rib structure  132  may act in concert with third cap member  136  to further allow enclosure  102  to acoustically decouple from locations of enclosure  102  associated with third audio device  134 , such as a portion contained by third rib structure  132 . Also, second rib structure  122 , third rib structure  132 , and fourth rib structure  142  may provide additional structural support and additional resistance to bending and/or twisting of enclosure  102 . This may further allow for a decreased thickness of rear portion  108  of enclosure  102  to create additional space within electronic device  100  and/or reduce the cost of materials used. 
     Also, electronic devices, such as electronic device  100 , are susceptible to damage, particularly during a drop event, such as when a user drops the electronic device on a relatively hard or dense surface. These drop events may cause a load force within electronic device  100  sufficient to cause cover glass  104  (shown in  FIG. 1 ) to mechanically decouple from enclosure  102 . In particular, electronic device  100  may be more susceptible to decoupling in instances when a corner, such as first corner  152 , of electronic device  100  collides with a hard surface. However, in addition to providing the desired acoustic effects previously discussed, first rib structure  112  is further capable of dissipating at least some of the load force incurred during the drop event. In particular, a drop event may deliver a force to sidewalls  110  which may cause the decoupling of the cover glass. However, first rib structure  112  is configured to channel or distribute the force associated with the drop event to other portions of enclosure  102 , such as rear portion  108 , which may be better suited to dissipate the force. Further, when first cap member  116  is positioned in and secured (e.g., by adhesives) to first rib structure  112 , electronic device  100  may withstand additional load force. Further, protrusions  118 , when adhesively attached to rear portion  108  of enclosure  102 , add additional stiffness and rigidity to enclosure  102  by minimizing movement of first cap member  116  during the drop event. In this manner, electronic device  100  may be provided with sufficient support to prevent mechanical decoupling of components, such as cover glass  104 , from enclosure  102 . It should be understood that other rib structures, cap members, and protrusions of cap member provide may include substantially similar features and advantages previously described for first rib structure  112 , first cap member  116  and protrusions  118 , all of which improve the strength and integrity of electronic device  100  by providing additional resistance against drop events. 
     The rib structures, audio devices, cap members (including protrusion) may include different shapes. For example,  FIG. 2  illustrates first rib structure  112  having a two-dimensional shape different from second rib structure  122  corresponding to different two-dimensional areas. Accordingly, first cap member  116  includes a different two-dimensional shape than that of second cap member  126 . Also, first audio device  114  includes a different two-dimensional shape than that of second audio device  124 . Differences in shapes may be due in part to constraints within electronic device  100 . For example, first rib structure  112  and second rib structure  122  may be designed to allow internal components (e.g., processor, main logic board, memory, battery, wiring, etc.) to pass around and/or between first rib structure  112  and second rib structure  122 . This may allow for optimal positioning of internal components and/or to provide structural support to enclosure  102  in specific or unique locations. In other embodiments, the rib structures are substantially similar in shape. 
     Structural differences, however, may correspond to acoustical differences. For example, first audio device  114  may project sound waves into back volume  214  (shown in  FIG. 4 ) in a manner different from sound waves projected from second audio device  124  into a back volume defined by a volume enclosed between second rib structure  122  and second cap member  126 . In this regard,  FIG. 2  shows first cap member  116  having protrusions  118  having a different size than protrusions  128  of second cap member  126  such that the back volumes associated with first audio device  114  and second audio device  124  are substantially similar. In other words, back volume  214  may include a three-dimensional volume similar to that of the back volume associated with second audio device  124 . This may allow first audio device  114  to deliver a similar volume level (e.g., decibel level) to a user as that of second audio device  124 . In order to form similar back volume dimensions from different associated audio devices, in some embodiments, the shapes of protrusions  118  are different from protrusions  128 . For example, in some embodiments, protrusions  118  include four-sided configurations while protrusions remain substantially circular. In the embodiment shown in  FIG. 2 , an exemplary first protrusion  120  includes a diameter  154  smaller than diameter  156  of an exemplary second protrusion  130 . Further, first cap member  116  includes a different number of protrusions  118  than protrusions  128  of second cap member  126 . Also, to produce a desired acoustical effect (e.g., similar volumes from different audio devices), in some embodiments, the protrusions of the cap members are not aligned in rows and/or columns. In the embodiment shown in  FIG. 2 , both first cap member  116  and second cap member  126  include protrusions  118  and protrusions  128 , respectively, aligned in rows and columns. It should also be noted that overall structures combining to form the back volumes are structured to compensate for differences in size or audio capabilities of audio speakers such that electronic device distributes a consistent volume through multiple audio devices. Accordingly, electronic device  10  may include audio devices having substantially similar sizes, or at least one audio device (e.g., first audio device  114 ) may differ. 
       FIG. 2  further shows both first rib structure  112  and second rib structure  122  having different two-dimensional shapes than third rib structure  132  and fourth rib structure  142 . Such differences may be for any reason previously described for differences between first rib structure  112  and second rib structure  122  (e.g., constraints due to other internal components). However, third rib structure  132  and fourth rib structure  142  coupled with third cap member  136  and fourth cap member  146 , respectively, are designed to cooperate with third audio device  134  and fourth audio device  144 , respectively, such that third audio device  134  and fourth audio device  144  deliver a substantially similar volume level as that of first audio device  114  and second audio device  124 . In this manner, the four audio devices  114 ,  124 ,  134 , and  144  cooperate to provide electronic device  100  having a substantially similar level to provide consistent user experience in terms of sound. 
     In the embodiment shown in  FIG. 2 , the rib structures, audio devices, and cap member are positioned at their respective corners of electronic device  100 . However, these structures and components may be positioned in other areas (e.g., proximate to a midpoint of a sidewall) which may be suitable to accommodate for various internal components or to offer improved audio quality. The cutting tool (e.g., CNC tool) may be easily reprogrammed by changing the computer code to cut or remove material from a substrate to form an enclosure. Also, the rib structures are generally linear structures with bends or elbows between adjacent linear structures. In other embodiments, the rib structures may be rounded, or generally circular, for purposes of improving structural support of the enclosure and/or improve audio quality. 
     An electronic device may include other variations of rib structures and cap members. For example,  FIGS. 5 and 6  illustrate an embodiment of an electronic device having rib structure  222  and cap member  226 . Cap member  226  may be made from any material previously described for a cap member. 
       FIG. 5  illustrates a top view of rib structure  222  having cap member  226  positioned within rib structure  222 .  FIG. 6  illustrates a cross sectional view of cap member  226  shown in  FIG. 5 , taken along the line  6 - 6 , showing cap member  226  adhesively secured to rib structure  222 . As shown in the enlarged view, the outer peripheral region of cap member  226  is adhesively secured to flange  230  of rib structure  222  via adhesive  236 , forming part of the acoustic seal previously described. 
     Protrusions  228  may be adhesively secured to rear portion  232  of rib structure. For example, an exemplary first protrusion  234  shown in the enlarged view is attached to rear portion  232  via adhesive  238 . It will be appreciated that all protrusions  228  may be adhesively attached to rear portion  232  in a similar manner. This provides the electronic device with additional structural support as well as resistance to bending, twisting, and/or dropping of the electronic device. 
     The enlarged view also shows rib structure  222  and cap members  226  having dimensions such that a top surface of cap structure  226  is substantially flush, or co-planar, with respect to rib structure  222 . This may be due in part to the positioning of flange  230  formed during a material removal process, the thickness of cap member  226 , or a combination thereof. In other embodiments, cap member  226  includes a thickness such that cap member is proud, or extends above, rib structure  222 . In this manner, cap member  226  may include electrically conductive materials to form, for example, an electrically conductive path along cap member  226 . Alternatively, cap member  226  may be laser etched and subsequently include a conductive adhesive to create a path for electric current. 
     Cap member  226  generally has a height  240  approximately in the range of 1.2 to 1.8 mm. Further, cap member  226  may include thickness approximately in the range of 0.3 to 0.6 mm, preferably in the range of 0.4 to 0.5 mm. Also, in some embodiments, protrusions  228  are formed by removing material from cap member  226  by, for example, a CNC tool. In the embodiment shown in  FIGS. 5 and 6 , protrusions  228  are formed by extruding cap member  226  to a desired shape, such as the shape shown. In this manner, cap member  226  remains relatively light (in weight) while minimizing unused or wasted material during a material removal process. 
       FIGS. 7-9  illustrate embodiments of a cap member providing structural support without having protrusions.  FIG. 7  illustrates an enlarged portion of an electronic device having enclosure  302  with rib structure  312  having a portion capable of receiving a cap member (not shown). In this embodiment, rib structure  312  includes first rib  316  and second rib  318  positioned within portion rib structure  312 , and extending from a rear portion  320  of enclosure  302 . First rib  316  and second rib  318  may be formed from a material removal previously described for forming a rib structure such that first rib  316  and second rib  318  are formed from the same material as that of enclosure  302 . First rib  316  may be diagonal with respect to enclosure  302  in order to dissipate a force incurred when dropping the electronic device, particularly when dropped on corner  320 . However, first rib  316  may generally take on other shapes to provide a desired structural and/or acoustical support. Second rib  318  may be positioned not only to dissipate load forces incurred on the electronic device, but to also create a back volume to generate desired acoustical characteristics within rib structure  312 , e.g., consistent volume with other audio devices within the electronic device. 
     Also, first rib  316  and second rib  318  may include a height similar to that of protrusions shown in previous embodiments. In this manner, a cap member may be placed within rib structure  312  such that the cap member can be adhesively secured to rib structure  312  as well as first rib  316  and second rib  318 . In other embodiments, first rib  316  and second rib  318  are formed from a rigid material (e.g., metal, plastic) and adhesively attached to rear portion  308  of enclosure  302 . 
       FIGS. 8 and 9  illustrate alternate embodiments of an enclosure of an electronic device having a rib structure with several bosses, or protrusions, extending from the rear portion of the enclosure.  FIG. 8  illustrates an enlarged portion of an electronic device having enclosure  402  with rib structure  412  and bosses  414  on rear portion  420  of enclosure  402 . A cap member is removed to show bosses  414 . Bosses  414  may be formed from any material removal process previously describe for a rib structure such that bosses  414  are made from the same material as enclosure  402 . In other embodiments, bosses  414  are formed from a rigid material (e.g., metal, plastic) and adhesively attached to rear portion  408  of enclosure  402 . 
       FIG. 9  illustrates a cross sectional view of rib structure  412  taken along the line  9 - 9 . Cap member  426  is added to show securing means to rib structure  412 . The enlarged view shows an outer peripheral portion of cap member  426  adhesively secured to flange  422  of rib structure  412 . Also, each of bosses  414  may be adhesively attached to cap member  426 . For example, first boss  416  is adhesively attached to cap member  426  via adhesive  418 . 
     Despite the configurations shown in  FIGS. 7-9 , these embodiments may nonetheless be configured to produce an electronic device (e.g., electronic device  100 ) that includes two or more audio devices coupled to the rib structures which emit sound from the electronic device in a manner previously described, such as outputting similar volume levels. 
       FIG. 10  illustrates a top view of an embodiment of cap member  526  having several protrusions  528  in a relatively non-uniform pattern. In other words, protrusions  528  are not in columns or rows.  FIG. 11  illustrates a top view of an embodiment of cap member  626  having several protrusions  628  in a relatively non-uniform pattern, further having protrusions  628  of different shapes and sizes. For example, while first protrusion  632  and second protrusion  634  are substantially circular (from a top view), first protrusion  632  includes a diameter less than that of second protrusion  634 . Also,  FIG. 11  shows third protrusion  636  having a four-sided configuration while fourth protrusion  638  has a six-sided configuration.  FIGS. 10 and 11  are designed to illustrate that protrusions may be formed with various geometrical shapes and sizes which also produce a desired structural support as well as a desired acoustical configuration, both of which are previously described. 
       FIGS. 12-14  illustrate enlarged portions of cap members showing various patterns or configurations of fibers within the cap members. The fibers shown in  FIGS. 12-14  may be part of a composite material, including carbon fiber.  FIG. 12  illustrates cap member  726  having fibers  730  generally in an orthotropic configuration. For instance, first fibers  732  include a generally circular pattern while second fibers  734  are configured generally in a linear pattern.  FIG. 13  illustrates cap member  826  having fibers  830  arranged in a different orthotropic configuration. For instance, first fibers  832  are generally aligned in a first direction (e.g., vertical) while second fibers  834  are generally aligned in a direction perpendicular to the first direction (e.g., horizontal).  FIGS. 12 and 13  may be used to resist load forces created during a drop event in from multiple directions. Also, in other embodiments, the fibers (e.g., fibers  730  or fibers  830 ) may be arranged in a random pattern, i.e., with no discernable arrangement. 
       FIG. 14  illustrates cap member  926  having fibers  930  in a substantially diagonal direction. Fibers  930  oriented in this manner may be beneficial to resist a drop event instances when an electronic device is dropped and a corner (e.g., first corner  152 , in  FIG. 2 ). In this manner, the load force created during the drop enters the electronic device in the direction of fibers  930 . 
     Additional structural improvements may be integrated into an electronic device. In particular, the improvements can resist cracking of a sidewall and/or an anodization layer applied to an enclosure. For example,  FIG. 15  illustrates a portion of electronic device  1000  having enclosure  1002  with first rib structure  1012  and second rib structure  1022 , both of which integrally formed to rear portion  1008  and first sidewall  1010  through material removal techniques previously described. Also, enclosure  1002  may include third rib portion  1032  and fourth rib portion  1042  integrally formed to rear portion  1008  first sidewall  1010 . Also, third rib portion  1032  is integrally formed to first rib structure  1012  and fourth rib portion  1042  is integrally formed to second rib structure  1022 . In this manner, when electronic device is dropped in manner in which first sidewall  1010  collides with an object, third rib portion  1032  and fourth rib portion  1042  provide structural support to first sidewall  1010  as well as an anodization layer (not shown). Further, third rib portion  1032  and fourth rib portion  1042  may further resist twisting and/or bending in portions of enclosure  1002  proximate to third rib portion  1032  and fourth rib portion  1042 . 
       FIG. 16  illustrates a isometric view of the area denoted in  FIG. 15  as Section A, showing third rib portion  1032  and fourth rib portion  1042  integrally formed in the manner described in  FIG. 15 . To provide the structural support described, third rib portion  1032  and fourth rib portion  1042  may include a thickness similar to that of first rib structure  1012 . For example, third rib portion  1032  includes thickness  1034  substantially similar to thickness  1014  of first rib structure  1012 . 
     Previous embodiments illustrate various structures within a rib structure used to provide structural and acoustic enhancements. However, other structures may be positioned within a rib structure. For example,  FIG. 17  illustrates an enlarged portion of enclosure  1102  having acoustic foam  1104  within rib structure  1112 . Acoustic foam  1104  may be formed from materials such as polyether or polyester. This may be used to provide additional acoustical enhancements, such as sound absorption, in order to configure audio devices which output the same sound levels. Also, acoustic foam  1104  may provide discrete stiffening to a cap member (not shown) when the cap member is adhesively secured to rib structure  1112 . Also, in some embodiments, acoustic foam  1104  is a cored laminate construction having a honeycomb configuration. In some embodiments, the porous regions of acoustic foam  1104  are configured in a closed-cell configuration, thereby reducing the overall weight of enclosure  1102  and also providing increased stiffness.  FIG. 18  illustrates an enlarged portion of enclosure  1202  having first component  1204  and second component  1206  within rib structure  1212 . First component  1204  and second component  1206  may be selected from a memory device, a power supply, or a processor. In this manner, an electronic device may include an overall reduced footprint by using space within rib structure  1212  for components. Also, first component  1204  and second component  1206  may be adhesively secured to rear portion  1208  in order to provide structure support to enclosure  1202 . 
       FIG. 19  illustrates a flowchart  1300  showing a method for forming an enclosure of an electronic device. In step  1302 , a portion of an aluminum substrate is removed to form sidewalls. In some embodiments, the sidewalls have a first sidewall. In step  1304 , a portion of the sidewalls is removed to define a location that receives a cover glass. In step  1306 , a portion of the aluminum substrate is removed to define a rib structure having a first rib and a second rib. In some embodiments, the first rib and second rib are adapted to receive an audio device and a cap member. Also, in some embodiments, the first rib and the second rib both engage the first sidewall. Further, in some embodiments, a flange member may be machined within first rib and/or second rib to adhesively secure the cap member. Also, in some embodiments, an underpass may be machined within the first rib and/or second rib. Also, in some embodiments, a third rib may be integrally formed with at least the second rib; the third rib may be configured to be free of contact with the audio device and the cap member. In step  1308 , a first aperture in the first sidewall is removed. In some embodiments, the first aperture opens into a location between the first rib and the second rib. The first aperture may define an opening for the audio device to emit sound from the electronic device. 
     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: 20140924
Publication Date: 20180710
Grant Date: 20180710
Priority Date: 20140924
Inventors: LOBISSER, G. KYLE
KEATS, JASON S.
MIHELICH, RYAN J.
VIEITES, PABLO SEOANE
KENNEY, KEVIN M.
RAFF, JOHN
UTTERMANN, ERIK A.
KUNA, MELODY L.
ROSS, OLIVER C.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04R1/2888", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2201/029", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/2834", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2499/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2201/029", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/2834", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2499/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/2888", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 55527023