Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is a continuation of U.S. patent application Ser. No. 13/793,560, filed Mar. 11, 2013, which application claims the benefit of the filing date of U.S. Provisional Application No. 61/672,041 filed Jul. 16, 2012, the disclosures of which are incorporated by reference herein. 
     
    
     BACKGROUND 
       [0002]    Housings for portable notebook or clamshell-style computers can be made from a number of plastic panels or sections that are assembled onto a metal frame. The metal frame is structured to retain and attach together the computer&#39;s internal components. Such internal components can include a printed circuit board that carries the computer&#39;s central processor and any additional processors such as for graphics or the like as well as the computer&#39;s random-access memory (RAM). Additional components include batteries, input devices such as a keyboard and trackpad or the like, storage memory (such as a hard drive, solid-state drive, or the like, communications devices (such as for WiFi connection and networking), removable memory devices (such as CD- or DVD-R/W drives), and structures for external peripheral connections. 
         [0003]    In a frame-based housing structure, all such components can be affixed to the frame, which itself can be made up of several different parts. The components of the housing are in turn attached to the frame to provide a somewhat uniform external appearance and to provide protection for the internal components. In a notebook (or clamshell) configuration, the arrangement just described can make up a base unit that is configured to rest on a surface. Another assembly in the form of a lid, or display, housing can be attached to the base housing by a hinge. The lid housing can include a video display, which can be in the form of a LCD panel with various forms of backlighting associated therewith. Similar to the base housing, the display (and any other components also included within the lid housing) can be affixed to another frame to which other housing sections or panels are affixed to enclose the lid assembly. The hinge can be attached to both the frame of the lid and the frame of the base with portions thereof extending through openings between or within the housing sections or panels. 
         [0004]    The hinged attachment between the base and lid housings can allow the computer to be moved between open and closed configurations. The closed configuration being such that the lid is positioned against the base with the display and input devices positioned internally of the housing units for protection thereof during transportation. In the open configuration, the display is viewable and the input devices are accessible to the user. The lid can be rotated through a range of positions to provide for comfortable viewing of the display. 
         [0005]    Such frame-based housing configurations can be complicated to assemble and to disassemble for repair or maintenance reasons. Further, they can be bulky due to the number of components and the complex assembly patterns required. Further, the number of joints or connections between components can provide a number of potential failure areas that can reduce the overall strength and protection provided by such housings. 
         [0006]    While many notebook computers still use such a housing structure, other structures have been developed that seek to combine the utility of the frame into a part of the housing units and to reduce the overall number of exterior pieces that make up the housing. Such structures can be made from metal and can, for example, include in one unit the top wall of a base housing (that surrounds the keyboard) along with the front and side walls thereof. This unit can also have internal reinforcement and can include attachment structures (such as threaded holes) for attachment of the internal components). A separate unit can define the bottom wall of the base and can attach to the upper housing unit. Such structures can provide for easier assembly of components but can still include major failure locations along the large attachment areas between housing components. 
       BRIEF SUMMARY 
       [0007]    An aspect of the present disclosure relates to an electronic device. The electronic device includes at least one electronic component. The electronic device also includes a first housing of a single piece of material. The first housing defines a length, a width, and a height that is less than both the length and the width. Further, the housing has at least five side walls defining an internal cavity and an open end to the cavity that spans the width and height of the housing. The electronic component is contained within the cavity. A cover is removably affixed over the open end of the first housing so as to contribute to a retaining force applied on the electronic component therein. 
         [0008]    In an example, the single piece of material can be of metal. The first housing can be a base housing for a portable computer, and the cover can be a first portion of a hinge assembly. In such an example, the device can further include a lid assembly operatively connected to the base housing by the hinge assembly. The lid assembly can include a lid housing substantially of a single piece of metal and having at least five side walls defining an internal cavity and an open end thereto. The lid assembly can further include a display unit received within the cavity of the lid housing, and the hinge assembly can include a second portion removably affixed over the open end of the lid housing. 
         [0009]    At least one of the side walls of the first housing can include an opening to expose a portion of the electronic component. In such an example, the electronic component can be a trackpad assembly including a touch-sensitive surface, and the touch-sensitive surface can be exposed within the opening. Additionally or alternatively, the electronic component can be a keyboard assembly including a plurality of keys, and at least the keys of the keyboard assembly can be exposed within the opening. In a further example, the electronic component can include at least one external connection element, and the at least one external connection element can be exposed within the opening. 
         [0010]    The electronic component can be positioned within a space defined between two spaced apart and parallel ones of the side walls. In such an example the device can further include a shim member wedged between the electronic component and a first one of the two side walls to force at least a portion of the electronic component into contact with a second one of the two side walls. The shim member can be a portion of a second electronic component received within the internal cavity of the housing. Additionally or alternatively, at least one of the side walls can include a hole therethrough, and the electronic component can include a threaded hole therein aligned with the hole in the side wall. In such an example, the device can further include a screw passing through the hole in the housing and engaging with the threaded hole of the electronic component. The device can further include a support member contacting at least two of the side walls of the housing within the internal cavity. The support member can be assembled with the electronic component to secure the component within the housing. 
         [0011]    The electronic component can be one of a plurality of electronic components within the housing. At least some of such electronic components can contact at least one of the side walls, respectively and the at least some of the electronic components can contact each other along respective portions thereof to help retain the at least some of the electronic components in predetermined positions within the housing. The cover can exert a retention force on the electronic component to help retain the electronic component in a predetermined position within the housing. 
         [0012]    Another aspect of the present disclosure relates to an electronic housing assembly. The assembly includes a first housing unit of a single piece of metal. The first housing unit defining a length, a width, and a height that is less than both the length and the width, the housing unit having at least five side walls defining an internal cavity and an open end to the cavity that spans the width and height of the housing unit. The assembly further includes a cover removably affixed over the open end of the first housing unit. The first housing unit is made by a process including deep drawing a single, substantially flat sheet of a metal material in a direction away from the open end formed thereby. 
         [0013]    The assembly can include at least one electronic component received within the first housing unit, and the process of making the first housing unit can further include deep drawing the sheet of metal material into a form configured to receive the at least one electronic component therein. The electronic component can include a threaded hole therein, and the process of making the first housing unit can further include forming a hole through at least one of the side walls configured to align with the threaded hole in the electronic component. The process of making the first housing unit can further include forming an opening in at least one of the side walls to expose at least a portion of the electronic component. The opening can be formed by laser cutting, by milling, or by other processes. 
         [0014]    The deep drawing process can be carried out using a mold that can impart an outside form of the housing on the sheet of metal material. The outside form can include respective outside surfaces of the side walls of the first housing unit. The process can further be carried out using a tool that can impart an inside form of the first housing unit on the sheet of metal material. The inside form can include respective inside surfaces of the side walls that define the internal cavity. The outside form of the first housing unit imparted by the mold can be an initial outside form that can include initial outside surfaces of the side walls. In such an example the process can further include removing material from the first housing unit, including the initial outside surfaces of the side walls. Removing material from the first housing unit can be carried out by milling, grinding, polishing, or other processes. Removing material from the first housing unit can reduce a radius on a corner between adjacent side walls of the initial outside form. 
         [0015]    Another aspect of the present disclosure relates to a method for assembling an electronic device. The method includes inserting an electronic component into a first housing through an open end thereof. The first housing is of a single piece of metal, and defines a length, a width, and a height that is less than both the length and the width. The first housing has at least five side walls around an internal cavity and an open end to the cavity that spans the width and height of the first housing. The method also includes removably affixing a cover over the open end of the first housing so as to contribute to a retaining force applied on the electronic component therein. 
         [0016]    The cover can be a first portion of a hinge assembly and the first housing can be a base housing for a base assembly of a portable computer. In such an example, the method can further include attaching a lid assembly with a second portion of the hinge assembly. The hinge assembly can be configured for operatively connecting the display assembly to the base housing. The lid assembly can include a lid housing, and the method can further include inserting a display unit into the lid housing through an open end thereof. Further, the lid housing can be of a single piece of metal, and can define a length, a width, and a height that is less than both the length and the width. The lid housing can have at least five side walls around an internal cavity and an open end to the cavity that spans the width and height of the lid housing, and assembling the lid assembly with the second portion of the hinge assembly causes the second portion of the hinge assembly to contribute to a retaining force applied on the display unit therein. 
         [0017]    The method can further include forming an opening in at least one of the side walls of the first housing to expose a portion of the electronic component. In an example where the first housing is a base housing for a notebook computer, the electronic component can be trackpad assembly having a touch-sensitive surface. Further, the method can include moving the trackpad into a position within the base housing such that the touch-sensitive surface is exposed in the opening formed in the housing and is substantially flush with an outside surface of the side wall in which the opening is formed. 
         [0018]    The method can further include inserting a shim member between one of the side walls and the electronic component. The shim member can be a part of second electronic component, and inserting the shim member can include inserting the second electronic component through the open end of the first housing into the cavity. 
         [0019]    The method can further include inserting a plurality of electronic components into the first housing through the open end thereof such that the electronic components are in mutually contacting relationships among each other within the first housing. At least one electronic component can contact the cover and another electronic component can contacts a side wall opposite the cover. In such an example, the mutually contacting relationships among the electronic components can be such that a combination of electronic components spans a length between the cover and the opposite side wall. 
         [0020]    The method can further include forming the first housing from a single, flat metal sheet by deep drawing the sheet in a direction away from the open end formed thereby. The deep drawing process can be carried out using a mold that imparts an outside form of the first housing on the sheet of metal material. The outside form can include respective outside surfaces of the side walls of the first housing. The deep drawing process can further be carried out using a tool that imparts an inside form of the first housing on the sheet of metal material. The inside form can include respective inside surfaces of the side walls adjacent the internal cavity. 
         [0021]    Another aspect of the present disclosure relates to a method for making an electronic device housing. The method can include deep drawing a single, substantially flat sheet of a metal material in a first direction to form a first housing unit of a single piece of metal. The first housing unit can define a length, a width, and a height that is less than both the length and the width. The first housing unit can have at least five side walls defining an internal cavity and an open end to the cavity that spans the width and height of the housing unit such that the length of the housing extends in the first direction. The method can further include removably affixing a cover over the open end of the first housing unit. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]      FIG. 1  shows a portable computer according to an embodiment of the present disclosure; 
           [0023]      FIG. 2  shows a base housing unit that can be used as a portion of the portable computer of  FIG. 1 ; 
           [0024]      FIG. 3  shows a lid housing unit that can be used as a portion of the portable computer of  FIG. 1 ; 
           [0025]      FIG. 4  shows an exploded view of the portable computer of  FIG. 1  and various components that can be included therein; 
           [0026]      FIG. 5  shows a partial cutaway view of the portable computer of  FIG. 1 ; 
           [0027]      FIG. 6  shows a partial cross-sectional view of the portable computer of  FIG. 1 ; 
           [0028]      FIG. 7  shows portions of an apparatus that can be used to make portions of a housing for the portable computer of FIG.  1  in a method according to another embodiment of the present disclosure; 
           [0029]      FIG. 8  shows a step in the method including the apparatus portions of  FIG. 7  and a workpiece; 
           [0030]      FIG. 9  shows another step in the method wherein the apparatus is used to at least partially shape the workpiece; 
           [0031]      FIG. 10  shows the workpiece of  FIG. 9  during a subsequent method step for making a base housing; 
           [0032]      FIG. 11  shows the workpiece of  FIG. 10  during another subsequent method step for making a base housing; 
           [0033]      FIG. 12  shows a step of the method including assembling various electronic components into the base housing; 
           [0034]      FIG. 13  shows a detail view of a subsequent assembly step; 
           [0035]      FIG. 14  shows a detail view of another subsequent assembly step; 
           [0036]      FIG. 15  shows a base housing with various electronic components assembled therein; 
           [0037]      FIG. 16  shows the assembly of  FIG. 15  with a hinge unit further assembled therewith; 
           [0038]      FIG. 17  shows a display assembly aligned with the assembly of  FIG. 16  for assembly therewith; 
           [0039]      FIGS. 18A and 18B  show flowcharts illustrating steps in a method of making computer housing components according to an aspect of the present disclosure; and 
           [0040]      FIG. 19  shows a flowchart illustrating steps in a method of assembling housing components with other components to make a computer according to an aspect of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0041]    Turning to the drawings,  FIG. 1  shows a portable computer  10  in the form of a “notebook” or “clamshell” computer with a base  12  configured to rest on a surface and to support a lid  14  including a screen  16 . Lid  14  is connected to base  12  by a hinge  18  that allows the lid  14  to close against the base  12  and to be opened by rotation away therefrom into a user-selectable viewing position during use of the computer  10 . 
         [0042]    Base  12  includes a keyboard  72  and a trackpad  70  for user input to computer  10 . The trackpad  70  can also be referred to as a touchpad and can include any type of touch-sensitive input, operating by capacitive, magnetic, resistive, surface-acoustic wave or other forms of touch-sensitivity. Both the keyboard  72  and trackpad  70  are mounted to base so that they are exposed at (or otherwise available for user interaction on) an outside surface of the upper wall  26  of the base  12 . It is noted that the terms “upper”, “lower”, and other terms related to relative positions of elements are done with respect to the frame of reference depicted in  FIG. 1 . Such terms are used for convenience and do not limit the actual positions of the elements should the device be repositioned. 
         [0043]    Base  12  includes a housing  24 , shown in  FIG. 2 , that consists of a unitary material structure that includes the upper wall  26 , a lower wall  28  that is spaced apart from and opposes upper wall  26 , a front wall  30 , and two side walls  32  and  34 , that extend generally vertically between the upper wall  26  and lower wall  28 . In such a unitary structure, a single piece of material includes the aforementioned walls,  26 ,  28 ,  30 ,  32 , and  34  with any one of these walls being solidly, or unitarily, connected with the adjacent walls by continuous, uninterrupted, sections of the same material. For example, the housing  24  can be made from a single piece of plastic or metal wherein the walls are integrally formed with the adjacent walls without any joining in the form of fastening, gluing, welding, or metallic joining such as soldering, braising or the like. Plastic materials can include polycarbonate (PC), ABS, PCABS, or the like. Metal materials can include aluminum, aluminum alloy, magnesium alloys, stainless steel, or the like. Such a housing with the described solid connections between walls can be made by injection molding metal or plastic, by die-casting metal or by a deep drawing process applied to a metal sheet, as described below. 
         [0044]    As further shown in  FIG. 2 , housing  24  defines an open end  36  opposite front wall  30  and bounded by edges of the upper  26 , lower  28 , and side walls  32  and  34 . Open end  36  provides access to an interior  38  of base housing  24  that is configured to enclose various internal components of the computer  10 . Base housing  24  also includes a keyboard opening  40  and a trackpad opening  42  that generally follow the facial profiles of the respective keyboard  72  and trackpad  70  such that they can be assembled therein and accessed by a user. A number of peripheral connection openings  43  to the interior  38  can also be included in housing  24 , for example through either of the side walls  32  or  34 , and can allow for access to peripheral connections for computer  10  such as for a power adapter plug, a USB device, one or more memory cards, audio devices, or the like. 
         [0045]    Housing  24 , when configured as a single piece of material that includes upper wall lower wall  28 , front wall  30 , and side walls  32  and  34 , can be stronger than other notebook computer housing structures. In particular, the torsional strength (or resistance to axial twisting, can be increased relative to multi-part housing structures. This can make the housing  24 , and accordingly the computer  10  overall, more resistant to, for example, being dropped on a side edge or a corner. Additionally, such a housing configuration can make the assembly process of the computer  10  easier and can further enhance the visual appearance of the computer  10  by eliminating parting lines, seams, or fasteners associated with assembling multiple components into a single housing. 
         [0046]    Lid  14  can also include a housing  44  configured with multiple, solidly joined, walls of a single piece of material. In the example shown in  FIG. 3 , lid housing  44  is a solid, or unitary, piece of material that defines an upper wall  46  that is generally positioned away from the upper wall  26  of the base housing  24  when lid  14  is in the closed position. Lid housing  44  also includes a bezel wall  48  that is positioned opposite from upper wall  46  and is spaced apart therefrom. Bezel wall  48  can be configured to surround at least part of the display screen  16  associated with lid  14 . As further shown in  FIG. 5 , bezel wall  48  can help retain a display assembly  60  that is configured to be positioned within lid housing  44 . As such, bezel wall  48  can oppose upper wall  46 , which can contact display assembly  60  on a side thereof opposite bezel wall  48 . 
         [0047]    Lid housing  44  also defines an open end  56  that is positioned opposite front wall  50 . Open end  56  is bounded by edges of the upper wall  46 , the side walls  52  and  54 , and at least portions of bezel wall  48 . In the example shown in  FIG. 3 , bezel wall is solidly joined with and extends inwardly from both side walls  52 ,  54  and front wall  50 . Lid housing  44  also defines a display opening  58  through which at least the screen portion  16  of the display assembly  60  is viewable by a user. The distance by which bezel wall  48  extends inward can vary depending on the configuration of, for example, display assembly and/or the materials from which lid housing  44  is constructed. 
         [0048]    In the example shown in  FIG. 3 , bezel wall  48  bounds open end  56  only along the distance by which the respective portions thereof extend inward from side walls  52  and  54 , leaving a portion of open end  56  unbounded. Such an arrangement is also such that display opening  58  only bounds screen  16  on three sides thereof and is open to a portion of open end  56 . In other embodiments, bezel wall  48  can extend from one side wall  52  to the other side wall  54  such that a portion of bezel wall  48  separates display opening  58  (which can be bounded on four sides) from open end  56 . 
         [0049]    As shown in  FIGS. 1 ,  4 , and  6 , a hinge assembly  18  can connect base  12  with lid  14 . Hinge assembly  18  can include a base portion  62  ( FIG. 6 ) that is configured to attach with base housing  24  and to cover open end  36  thereof. Similarly, a lid portion  64  of hinge assembly  18  can attach with lid housing  44  to cover open end  36  thereof. A joint  66  or a plurality of joints  66  can connect base portion  62  to lid portion  64  and can be configured to allow base portion  62  to articulate with lid portion  64  to provide the desired range of rotation between base  12  and lid  14 . The example of joint  66  shown in the figures is in the form of a barrel, or piano, style hinge, but other forms of notebook computer hinges can be implemented in a similar structure. 
         [0050]    As shown in  FIGS. 4-6 , base housing  24  and lid housing  44  can be configured to work with base portion  62  and lid portion  64 , respectively, of hinge assembly  18  to retain appropriately-configured internal components therein. Specifically, base housing  42  can be configured to retain one or more batteries  68 , a trackpad assembly  70 , a keyboard assembly  72 , and a board assembly  74 . These components can be configured to contact one another, various portions of the interior  38  of base housing  24 , and portions of a surface of hinge base portion  62  that cover open end  36  such that the components are retained within base housing  24  and are secured in their respective positions. 
         [0051]    As shown in the exploded view of  FIG. 4 , the components as well as interior  38  of base housing  24  can be configured such that the components can be slid into base housing  24  through open end  36  thereof. The components can further be configured such that they engage with each other and with base housing  24  such that the positions of the components are maintained once assembled in a particular manner. In the example shown in  FIG. 4  and in the cutaway view of  FIG. 5 , the one or more batteries  68  can be configured to contact the interior of lower wall  28  and the front wall  30  along portions thereof. For instance, batteries  68 A and  68 C can be configured to contact respective portions of the adjacent ones of side walls  32  and  34  with battery  68 B positioned between and in mutual contact with batteries  68 A and  68 C. The batteries  68  can be configured to be spaced apart from the interior of upper wall  28 . This configuration can allow for trackpad assembly  70  to be positioned between at least portions of the batteries  68  and upper wall  28 . 
         [0052]    Trackpad assembly  70  can include various sub-components commonly associated with trackpads or other touch-sensitive input devices. This can include a touch sensitive substrate  76  that defines the actual surface with which the user interacts. The trackpad assembly  70  can also include a support structure  78  that can retain substrate  76  and can include associated circuitry or other functionality, such as structures to provide a clickable trackpad surface or the like. Support structure  78  can be configured to extend outwardly around substrate  76  such that substrate  76  can fit within opening  42  with support structure contacting the portion of upper wall  26  that surrounds opening  42 . Opposite the upper wall  26 , support structure  78  can contact one or more of the batteries  68 . In such a configuration, batteries  68  and support structure  78  can be configured such that, when stacked atop one another, they extend completely between lower wall  28  and upper wall  26 . This can, among other things, retain the position of trackpad assembly  70  through a combination of the fit of substrate  76  within opening  42  and the friction generated between the batteries  68 , the trackpad assembly  70  and the upper and lower walls  26  and  28 . 
         [0053]    Similar to trackpad assembly  70 , keyboard assembly  72  can be structured to engage with keyboard opening  40 . As illustrated in  FIGS. 5 and 6 , keyboard assembly  72  can include a support structure  73  with a raised portion  80  surrounded by an outwardly extending flange portion  82 . Keyboard support structure  73  can be configured such that raised portion  80  fits within keyboard opening  40  and such that flange  82  can contact the interior surface of upper wall  26  when raised portion  80  is within opening  40 . Support structure  73  can also support the various keyboard keys  84  and any related circuitry such that keyboard assembly  72  can be a self-contained unit. 
         [0054]    Further, board assembly  74  can be configured to fit between keyboard support structure  73  and the interior surface of lower wall  28 . As shown in  FIGS. 5 and 6 , keyboard assembly and board assembly  74  can be configured such that board assembly can contact the interior surface of lower wall  28  with keyboard support structure  73  being retained in a position such that raised portion  80  is within opening  40  and flange  82  is held in contact with upper wall  26  by board assembly  74 . 
         [0055]    As shown in  FIG. 4 , board assembly  74  can include a printed circuit board  86 , or a plurality of printed circuit boards attached together, supported on a common structure, or the like. The board  86 , shown in  FIG. 4 , can be in the form of a motherboard or the like that can provide interconnections between various semiconductor chips or other microelectronic elements that can be carried thereon as well as with external components, such as power supplies, memory, etc. In the simplified example shown in the figures, board  86  is shown including a microprocessor  88  carried thereon. The microprocessor  88  can implement various functionality of the computer  10 , including receiving user input, providing output either directly or through communication with a graphics processor or the like, and allocating memory usage and retrieving stored data from memory. Board  86  is also shown with a fan  94  thereon to provide cooling for the components within base  12 . The board  86  can also include one or more memory structures in the form of RAM or other similar components. The board  86  can also include connections for communication with the batteries  68 , the trackpad assembly  70 , the keyboard  72  and the display assembly  60 . 
         [0056]    Board assembly  74  can also include end units  90  that can be positioned on opposite sides of board  86  that are disposed toward the side walls  32 , and  34  of the base housing  24 . Additionally or alternatively, end units can be positioned along the sides of board  86  that extend between those adjacent the side walls. In another example, board  86  can be supported by or contained within a single housing unit that substantially covers a portion of the board  86  itself. As shown, end units  90  are configured to contact the lower wall  28  of base housing  24  on an interior surface thereof. End units  90  are also configured to respectively contact the interior surfaces of the side walls  32  and  34  with board  86  spacing apart end units  90  to maintain such contact. In this arrangement, board  86  can be supported in a position such that it does not directly contact the interior of base housing  24  and such that the delicate components carried thereon are isolated from coming into contact with other internal features of the base  12 , which could cause damage thereto. 
         [0057]    End units  90  can also include various input or output port structures  92 . Such ports  92  can include connections for an external power supply, or connections specially configured as, e.g., USB, Fire-Wire, HDMI, or other similar connections. Ports  92  can also include SD card reader slots, or audio input or output connections. The conductive features of the ports can connect with the circuitry of the board  86  for communication therewith. Further the ports  92  can align with port openings  43  in the base housing  24  such that components can connect with ports  92  through housing  24 . 
         [0058]    End units  90  can further be configured to provide the spacing necessary to maintain the desired position for keyboard assembly  73  discussed above. Specifically, when end units are positioned within base housing  24  such that they contact the interior of lower wall  28 , they can support keyboard assembly  72  on a side opposite lower wall  28  such that flange  82  contacts the interior of upper wall  26  with raised portion positioned within keyboard opening  40 . Such a configuration, can allow for board assembly  74  to be easily removed for repairs, upgrading (such as replacing or adding memory), or replacement with a similarly-configured board assembly  74  to be swapped for the existing board assembly. This can be done for purposes of repair, such as replacing a damaged board assembly  74  or upgrading, such as by replacing a board assembly  74  for a new board assembly  74  with, for example, a faster processor or the like. This configuration can also streamline custom manufacture of notebook computers, allowing for a number of pre-assembled board assemblies  74  with different processors, memory configurations, etc. to be provided and selected from according to customer-specifications during assembly of computer  10 . In addition, the above-described configuration of the other internal components can similarly provide for easier repair/replacement thereof. 
         [0059]    As discussed above, base portion  62  of hinge assembly  18  can be configured to close open end  36  of base housing  24  such that the internal components of base  12  are retained therein. As shown in  FIG. 6 , base portion  62  can be configured to contribute to the retention of the internal components of base  12  in their respective positions. In the example shown, wherein batteries  68  contact the interior of front wall  30  and board assembly  74  contacts batteries  68  opposite front wall  30 , an interior surface  96  of hinge base portion  62  can contact board assembly  74  opposite battery  68 . In this manner, these interior components of base  12  are in continuous contact between front wall  30  and surface  96  of hinge base portion  62 , which maintains the components in their positions therebetween. Other configurations for such internal components are possible in which continuous contact between components is maintained between front wall  30  and hinge base portion  62  and could be determined based on the particular components used and the general shapes thereof. 
         [0060]    Hinge base portion  62  can affix to base housing  24  by various fasteners that engage between base housing  24  and hinge base portion  62 . In the example of  FIG. 6 , one or more screws passes through lower wall  28  and engages with hinge base portion  62 . A similar screw can pass through upper wall  26  or one or both side walls  32  and  34 . Alternatively, snap-fit structures can be used to affix hinge base portion  62  with base housing  24 . As further alternatives, press-fit structures or adhesives can be used. 
         [0061]    Embodiments of hinge assembly  18  can include wire routing therethrough such that a connection can be made, for example, between board assembly  74  and display assembly  60  to supply power and a video signal to display assembly  60 . Additionally, wire segments can be included with hinge assembly  18  that extend from base portion  62  and lid portion  64  thereof for connection with wire segments connected with board assembly  74  and display assembly  60 , respectively. Similar wiring can be present among components within base housing  24  to connect, for example board assembly  74  with trackpad assembly  70  and/or keyboard assembly  72 . Additionally or alternatively, conductive connections can be positioned on adjacent components so that, when assembled into base housing  24 , electrical connection is achieved between components, for example battery  68  and board assembly  74 . Hinge base portion  62  can also include an opening or openings that align with an output of fan  94  to allow air to pass therethrough. 
         [0062]    Compliant inserts  100  can be positioned between various internal components of base  12 . These inserts  100  can be compressible and can be made of various foams, rubbers, elastomers or the like. The presence of inserts  100  between components or between a component and one of the walls of housing  24  can take up extra space between components or between a component and a wall that can arise due to manufacturing tolerances. This can allow for a more precise fit of components within housing  24  and can minimize the movement of components within housing  24  without requiring particularly tight tolerances of the components or of housing  24 . These inserts  100  can be affixed to or assembled with the various components in strategic positions. For example, as shown in  FIG. 6 , an insert  100  can be affixed to battery  68  at a location such that insert  100  will be positioned between front wall  30  and battery  68 . As also shown, another insert  100  can be attached to keyboard assembly  72  in a position to contact surface  96  of hinge base portion  62 . Additional inserts  100  can be affixed to either trackpad assembly  70  or board assembly  72  to contact the other of these components. Still further inserts  100  can be positioned between battery  68  and trackpad  70 , between board assembly  74  and keyboard assembly  72 , or between any of the components and upper wall  26 , lower wall  28 , or side walls  32  and  34 . 
         [0063]    As shown in  FIG. 6 , one or more wedge elements  102  can also be assembled within base housing  24  adjacent one or more of the above-described internal components. The use of such wedge elements  102  can help to retain the desired positions of the internal components within base housing  24 . In the example shown in  FIG. 6 , wedge element  102  is positioned beneath a battery  68  such that on one side it contacts battery  86  and, on the other, it contacts the interior surface of lower wall  28 . As also shown, the portion of battery  68  that wedge element  102  contacts can include an inclined surface  104  that is configured to mutually contact the wedge element  102  along a portion of the area thereof. This can allow for more even contact of battery  68  with, for example, trackpad assembly  70  on the side opposite wedge element  102 . By using wedge elements  102  as shown, battery  68  can be pushed by wedge element  102  toward upper surface  26  of base housing  24 , creating pressure of trackpad assembly  70  against the interior of upper wall, between trackpad assembly  70  and battery  68 , and the like. This increase of pressure creates friction between the components and between the components and the upper  26  and lower walls  28 , which can help maintain the positions of the components. 
         [0064]    Additional wedge elements  102  can be positioned between, for example board assembly  74  and lower wall  28 , between battery  68  and trackpad assembly  70 , between board assembly  74  and keyboard assembly  72 , or between any other adjacent components. Accordingly, board assembly  74 , trackpad assembly  70 , keyboard assembly  72 , and any other components can also include inclined surfaces similar to surface  104  of battery  68 . Further, wedge elements  102  can be attached to or integrally formed with, for example, board assembly  74  or hinge base portion  62  in the appropriate location to engage with, respectively battery  68  and board assembly  74 . In another example, board assembly  74  itself can have a surface thereof that acts like a wedge and is configured to contact an appropriately configured inclined surface on keyboard assembly  72 . 
         [0065]    As shown in  FIG. 4 , lid housing  44 , the structure of which is described above with respect to  FIG. 3 , is configured to receive a display assembly  60  therein. Display assembly  60  can include a computer screen  16  and various electronic components associated therewith. In an example, display assembly  60  can include a screen  16  in the form of an LCD screen and an associated light source, such as fluorescent lights, LED lights, or an OLED panel. Display assembly  60  can also include various components that are not necessarily associated with the display itself but can be strategically positioned within lid housing  44 . Such components can include WiFi or cellular data (such as 3G, 4G, or LTE) antennae. Various electronic shielding structures can also be included in display assembly  60 . 
         [0066]    Display assembly  60  can be configured to be received within lid housing  44  such that a viewable area of screen  16  is aligned within display opening  58 . Further, display assembly  60  can include one or more strategically positioned compliant inserts  100  similar to those discussed above with respect to base housing  24 , above. As with the components of base  12 , such inserts can serve to compensate for mechanical tolerance build up between display assembly  60  and lid housing  44  and can serve to provide a pressure-fit therebetween. Still further, wedge elements  102  similar to those described above with respect to  FIG. 6  can also be positioned between display assembly  60  and lid housing  44 . 
         [0067]    As also shown, hinge assembly  18  includes a lid portion  64  ( FIG. 6 ) that is attached to base portion  62  by joint  66 , as described above. Hinge lid portion  64  is configured to assemble with lid housing  44  such that hinge lid portion  64  encloses the open end  56  of lid housing  44 . In doing so, hinge lid portion  64  can secure display assembly  60  within lid housing  44  by contacting a portion of display assembly  60  adjacent open end  56 . Additional foam inserts, such as inserts  100  shown in  FIG. 6  can compensate for mechanical tolerances between hinge lid portion  64  and display assembly  60  and/or between display assembly  60  and the interior of front wall  50  of lid housing  44 . Further, hinge lid portion  64  can include a raised portion  65  ( FIG. 12 ) that can span any open distance between portions of bezel wall  48  and that are respectively adjacent the side walls  52  and  54 . Such a portion  55  can be substantially flush with bezel wall  48  in the assembled computer  10  and can bound a bottom edge of the screen  16 . 
         [0068]    As discussed above, base and lid housings  24  and  44  having of a single piece of material and being solidly joined between walls of the type described herein can be made from various materials including various metals or plastics using various fabrication methods.  FIGS. 7-11  show various stages in one method for making the base housing  24  and the lid housing  44  for computer  10 . Additionally,  FIGS. 12-17  show various stages in making base assembly  12  and lid assembly  14  as fabricated by any means, including deep drawing as well as other processes, and assembling computer  10  from these assemblies. These steps are further depicted in the flowcharts shown in  FIGS. 18A ,  18 B, and  19 . 
         [0069]    In the deep drawing example of  FIGS. 7-11 ,  18 A and  18 B, base housing  24  and lid housing  44  can be made using a tool  106  and a mold  108  as shown in  FIG. 7 . Tool  106  can be generally in the shape desired for the interior  38  of base housing  24  and mold  108  can include a cavity  110  that is generally in the negative of a shape desired for the outer surfaces of base housing  24 . The tool  106  and mold  108  can be configured to be used with machinery (not shown) that is specifically adapted to carry out a deep drawing process using tool  106  and mold  108 . The tool  106  and mold  108  can also be configured to form housings  24  of various designs, sizes, shapes or other configurations, in addition to the variation of housing  24  shown in the Figures. 
         [0070]    As shown in  FIG. 8 , a workpiece  24 ′ in the form of a generally flat metal sheet can be positioned between the tool  106  and the mold  108  when the tool  106  and the mold  108  are in a pre-forming position with tool  106  withdrawn from cavity  110  (step  202  in  FIG. 18A ). The workpiece  24 ′ can be of any of the above-described materials suitable for the formation of base housing  24  and can have a thickness that is approximately equal to the desired thickness for the various walls of base housing  24 . In some embodiments, the initial thickness of workpiece  24 ′ can be thicker than the desired final wall thickness for base housing  24  to compensate for a reduction in material thickness due to stretching of the material during the drawing process or to compensate for material removal in optional finishing processes, described below. In an example, the above-described process can be carried out to achieve a final material thickness of about 0.6 mm (+/−5%) for a base housing  24  or a lid housing  44  made from stainless steel or about 0.8 mm (+/−5%) for a base housing  24  or lid housing  44  made from aluminum. In other examples wherein base housing  24  or lid housing  44  is made from various plastics, the fabrication processes associated therewith can be configured to achieve a final material thickness of between about 1.5 mm and 2 mm (+/−5%). 
         [0071]    In the deep-drawing process, the tool  106  is driven into cavity  110  with workpiece  24 ′ positioned between tool  102  and mold  108  (step  204  in  FIG. 18A ), which can be done by application of constant pressure thereto or by repeated impacting of tool  106  into cavity  110 . This driving action causes plastic deformation of workpiece  24 ′ as it is pushed into the shape of the area defined between tool  106  and cavity  110 , as shown in  FIG. 9 . As shown, the driving direction of tool  106  is generally carried out in a direction between what will be the open end  36  and the front wall  30  of the housing  24 . The driving process and the accompanying deformation process can be continued until the workpiece  24 ′ reaches the end of the cavity  110 , which generally gives the form of font wall  30 . At such a point, the tool  106  can then be withdrawn from the cavity  110  and the deformed workpiece  24 ′ removed from either the cavity  110  or the tool  106 . In an embodiment, workpiece  24 ′ can be heated prior to the deformation process described above. Such heating can be carried to make the workpiece  24 ′ more pliable (but while still remaining solid) and, therefore, more amenable to the deep drawing process. 
         [0072]    As shown in  FIG. 10 , the deformed workpiece  24 ′ can include excess material  112  around what will be open end  36  upon removal from the mold  108  (step  206  in  FIG. 18A ). As shown in  FIG. 11 , this excess material  112  can be removed by cutting, which can be done by a saw, by a laser or the like, or by a machining process (step  208  in  FIG. 18A ). After such removal, workpiece  24 ′ can have the general shape desired for base housing  24 , including upper wall  26 , lower wall  28 , front wall  30 , and side walls  32  and  34  as well as open end  36 , as shown in  FIG. 11 . 
         [0073]    Subsequently, trackpad opening  42 , keyboard opening  40  and port openings  43  can be formed in workpiece  24 ′ (step  212  in  FIG. 18A ), resulting in the structure of housing  24  shown in  FIG. 2 . This can be done by laser cutting, by machining, or by a combination of drilling and physical cutting using a saw or the like. A similar process using an appropriately-configured tool and mold combination can also be used to make lid housing  44 , which can also include cutting an appropriately-shaped display opening  60  (steps  203 - 213  in  FIG. 18B ). In the above-mentioned injection-molding and die-casting process, the keyboard, trackpad, and display openings  40 ,  42 , and  60  can be formed in connection with such molding by including these features in any molds used. Alternatively, these openings  40 ,  42 , and  60  can be formed in subsequent steps, as described in connection with the deep drawing process. 
         [0074]    Additional finishing processes can be applied to base housing  24  at any point after formation thereof. Such processes include machining the exterior thereof to remove excess wall thickness or to give a particular shape such as by reducing corner radii or the like (steps  210  in  FIG. 18A and 211  in  FIG. 18B ). Additionally, the exterior of base housing  24  can be anodized, painted, sealed or otherwise treated. 
         [0075]    After formation of base housing  24  and lid housing  44 , the various internal components of computer  10 , which can be done according to the deep drawing process, as described above, or the previously mentioned injection molding or die-casting methods, can be assembled into the respective housings (steps  214 - 216  in  FIG. 19 ). As shown in  FIG. 12 , the various components associated with base housing  24  can be inserted thereinto through open end  36 . The components can be inserted in stages and positioned as desired before subsequent components are placed into housing  24 . In an example, trackpad assembly  70  can be placed into housing  24  first and positioned within opening  42 , after which batteries  68  can be positioned adjacent front wall  30  and beneath trackpad assembly  70  (step  214  in  FIG. 19 ). Electrical connections between components can be made during assembly, such as by attachment of mutually-engaging plugs or outlets or the like. 
         [0076]    Subsequently, keyboard assembly  72  can be inserted within housing  24  through open end  36 , as shown in  FIG. 12  (step  216  in  FIG. 19 ). Keyboard assembly  72  can then be positioned such that raised portion  80  is aligned with keyboard opening  40 , as shown in  FIG. 13 . Keyboard assembly  72  can then be moved such that flange  82  contacts the interior of upper wall  26  and raised portion  80  is positioned within opening  40 , as shown in  FIG. 14 . As explained above, the fit of raised portion  80  within opening  40  can keep keyboard assembly  72  appropriately positioned with within opening while flange  82  is maintained in contact with the interior of upper wall  26 . By inserting board assembly  74  into the space between keyboard support  73  and the interior of lower wall  28 , as discussed above, keyboard assembly  72  can be maintained in such a position. 
         [0077]    Hinge assembly  18  can then be assembled with base assembly  12 , as shown in  FIG. 16 , by attaching hinge base portion  26  to the open end  36  of base housing  24  (step  218  in  FIG. 19 ). As discussed above, hinge base portion  26  can be configured to contact a portion of board assembly  74  such that the internal components of base  12  are maintained in desired positions thereof. It is noted that, in embodiments where wires are included in and through hinge assembly  18 , such wires can be connected with other wires that can extend from, for example, board assembly  74  prior to attaching hinge assembly  18  to base housing  24 . As discussed above, hinge base portion  62  can be attached to base housing  24  by screws, snap-fit or press-fit structures, adhesives or the like. 
         [0078]    As discussed above, lid housing  44  can be made in a manner similar to that of base housing  24 . In an example using deep drawing, lid housing  44  can be made by deep drawing a sheet of metal in a direction away from what will become open end  56 . Subsequently, display opening  58  can be cut in bezel wall  48 , as discussed above (step  213  in  FIG. 18 ). Display assembly  60  can then be assembled with lid housing  44  resulting in lid assembly  14  (step  215  in  FIG. 19 ). Lid assembly  14  can then be assembled with hinge assembly  18  by attaching hinge lid portion  64  to open end  56  of lid housing  44 , which can be done in a similar manner to the attachment of hinge base portion  62  with open end  36  of base housing  24  (step  217  in  FIG. 18 ). Any wires that require connection between display assembly  60  and hinge assembly  18  can be connected prior to the attachment of hinge lid portion  64  with open end  56 . It is noted that base assembly  12 , lid assembly  14 , and hinge assembly  18  can be conducted in parallel or in any sequence desired before assembly together. Further, lid assembly  14  can be assembled with hinge  18  before assembly with base  12 , if desired. Additional finishing steps can also be carried out after the computer has been assembled, including cleaning, painting, packaging, battery charging, etc. (step  219  in  FIG. 18 ). 
         [0079]    Housings of a similar configuration to those described above in the context of a notebook computer can be used in other electronic devices as well. For example, a similar configuration of two assemblies including single-piece housings of the general form discussed above and connected with a hinge that covers open ends of the housings can be implemented in mobile telephones. In other examples, a single assembly having a single housing of the type discussed above with a cover over an open end thereof that helps maintain various positions of internal components of the device can be used in smartphones, tablet computers, e-readers or the like. Further, such housing configurations can be implemented in peripheral electronic devices, including keyboards and the like. 
         [0080]    Although the description herein has been made with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present disclosure as defined by the appended claims.

Technology Category: 4