Systems and methods for overmolding on an electronic device surface

Abstract

An electronic device comprising a display having a glass planar portion and a second material positioned at an outer edge of the glass planar portion. The glass planar portion defines a majority of a display surface of the display, and the second material is molded to the outer edge of the glass planar portion and defines at least a portion of a border portion. The second material is curved in a direction perpendicular to the display surface. The second material is comprised of a first plurality of segments and a second plurality of segments. Each segment of the second plurality of segments is interposed between adjacent segments of the first plurality of segments, and the first plurality of segments interlocks with the second plurality of segments.

Description

Background Technology

[0001] Background and related technologies

[0002] As electronic devices become smaller and lighter, more and more of them are operated primarily in the user's hand. The display cover or other outer surfaces of conventional electronic devices are flat. The abrupt corners of flat surfaces are uncomfortable for the user. To produce smaller and lighter electronic devices, the bezels or borders around the display are constantly being reduced to more efficiently utilize the surface area of ​​the electronic device. Forming display cover or other housing surfaces with curved panel edges increases costs. Applying a second boundary material around the display cover or other housing surface to create a smooth, curved boundary introduces stress on the display cover or other housing surface during manufacturing and throughout the device's lifespan, potentially leading to damage to the display cover or other housing surface. Summary of the Invention

[0003] In some embodiments, an electronic device includes: a display having a glass planar portion and a second material location at an outer edge of the glass planar portion. The glass planar portion defines a majority of the display surface, and the second material is molded to the outer edge of the glass planar portion and defines at least a portion of a boundary portion. The second material is bent in a direction perpendicular to the display surface. The second material is composed of a first plurality of segments and a second plurality of segments. Each of the second plurality of segments is inserted between adjacent segments of the first plurality of segments, and the first plurality of segments interlock with the second plurality of segments.

[0004] This summary is provided to introduce, in a simplified form, a selection of concepts also described in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help determine the scope of the claimed subject matter.

[0005] Additional features and advantages will be set forth in the following description, and in part will be obvious from the description, or may be learned by practice of the teachings herein. The features and advantages of this disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. The features of this disclosure will become more apparent from the following description and the appended claims, or may be learned by practice of this disclosure as set forth below. Attached Figure Description

[0006] To describe how the features listed above and others of this disclosure can be obtained, a more specific description will be presented by reference to particular embodiments illustrated in the accompanying drawings. For better understanding, the same elements have been designated by the same reference numerals throughout the drawings. Although some drawings may be schematic or exaggerated representations of concepts, at least some drawings are drawn to scale. It will be understood that the drawings depict some exemplary embodiments, which will be described and explained with additional features and details using the drawings, in which:

[0007] Figure 1-1 This is a perspective view of an electronic device according to at least one embodiment of the present disclosure;

[0008] Figure 1-2 According to at least one embodiment of this disclosure Figure 1-1 Side detail of the electronic device;

[0009] Figure 2 This is a perspective view of 2D glass, 2.5D glass and 3D glass according to at least one embodiment of the present disclosure;

[0010] Figure 3 This is a front view of a tablet computer according to at least one embodiment of the present disclosure;

[0011] Figure 4 This is a front view of a television remote control according to at least one embodiment of the present disclosure;

[0012] Figure 5 This is a top view of a main body panel having segmented boundary portions according to at least one embodiment of the present disclosure;

[0013] Figure 6 This is a side sectional view of a main body panel having a curved boundary portion according to at least one embodiment of the present disclosure;

[0014] Figure 7 This is a flowchart illustrating a method of manufacturing an electronic device according to at least one embodiment of the present disclosure;

[0015] Figure 8 This is a front view of a main body panel having boundary portions in the form of a first plurality of segments according to at least some embodiments of the present disclosure; and

[0016] Figure 9 It is a second plurality of segments having boundary portions according to at least some embodiments of this disclosure. Figure 8 The front view of the main panel. Detailed Implementation

[0017] This disclosure generally relates to systems and methods for providing a body panel of an electronic device having a curved boundary portion. More specifically, this disclosure relates to a body panel comprising a first material connected to a boundary portion comprising a second material different from the first material. The boundary portion is formed in segments during assembly and applied to the first material to mitigate stresses in the first material associated with shrinkage of the second material, which is related to cooling and / or curing of the second material. Shrinkage of the second material surrounding the body panel can damage the body panel itself, and residual stresses associated with shrinkage can make the body panel more susceptible to damage during use or transport of the device.

[0018] In some embodiments, an electronic device has at least one substantially planar body panel that includes a portion of a first surface of the device. In some embodiments, the body panel includes a large portion of the first surface of the device. In some embodiments, the electronic device has a complementary second body panel that is substantially planar and includes a portion of a second surface of the device. In some embodiments, the electronic device has a complementary second body panel that is substantially planar and includes a large portion of the second surface of the device. In some embodiments, the first body panel and the second body panel are parallel to each other. In some embodiments, the first surface is a top surface and the second surface is a bottom surface. In some embodiments, the first surface is a front surface and the second surface is a rear surface.

[0019] Figure 1-1 and 1-2 An embodiment of an electronic device 100 having a display cover 102 on a first surface and a metal body panel 108 on an opposing second surface has been described. Figure 1-1 This is a perspective view of the display cover 102 of the planar portion 104 defined by the boundary portion 106 of the electronic device 100. Figure 1-2 yes Figure 1-1 A side view of the electronic device 100 shows a boundary portion 106 positioned at the edge of a planar portion 104 defined by a display cover 102 and a metal body panel 108. The boundary portion 106 provides the electronic device 100 with a curved and continuous surface extending from the planar portion 104 of the display cover 102 surrounding the side of the electronic device 100 to the planar portion 104 of the metal body panel 108 on the back of the electronic device 100.

[0020] In some embodiments, a portion or a majority of the body panel forming the first surface is completely planar. In some embodiments, the body panel is substantially planar because at least 90% of the surface of the body panel lies in or deviates from a single plane by 10%. Figure 2Examples of planar or substantially planar glass sheets are explained. In some embodiments, the planar portion 204-1 of the electronic device is entirely planar, such as two-dimensional (2D) glass. In some embodiments, the planar portions 204-2, 204-3 of the electronic device have curved regions adjacent to the flat surface, such as... Figure 2 The 2.5D and 3D glass described herein. In some embodiments, the first surface of the electronic device has a non-planar portion separate from the display cover or other main body panel, such as a keyboard, trackball, touchpad, other physical input mechanism, textured grip, other raised or recessed portions, or other continuous or discontinuous areas that are not coplanar with the planar portion of the first surface.

[0021] In portable electronic devices, the device is typically held in the user's hand. A curved side of the electronic device provides a more comfortable grip. Flat body panels can be significantly cheaper and easier to manufacture than curved body panels. In some embodiments, attaching a flat body panel to the boundary portion of another part of the electronic device housing (e.g., a side panel, a complementary second body panel, or a barrel containing electronic components) can reduce costs, simplify assembly, allow for additional product design options, or combinations thereof. In some embodiments, attaching a flat body panel to the boundary portion of another part of the electronic device housing can visually blend the boundary portion with the flat portion, giving the flat portion a curved appearance to the user.

[0022] In conventional electronic devices, continuous boundary portions can exert compressive or shear forces on the body panel because the material of the boundary portion shrinks due to the cooling or solidification of a secondary material over time. The segmented boundary portions according to this disclosure reduce the forces applied to the body panel, thereby allowing the use of larger areas and / or thinner body panels. In some embodiments, the boundary portion is applied to the outer edge of the body panel. In some embodiments, the boundary portion is secondary-molded onto the body panel. In some embodiments, at least a portion of the boundary portion is applied to a planar surface of the body panel. In some embodiments, the boundary portion is positioned around the complete outer edge (i.e., perimeter) of the body panel. In some embodiments, the boundary portion is positioned around a portion smaller than the complete outer edge of the body panel.

[0023] In some embodiments, the electronic device is a mobile electronic device, such as a smartphone or personal media device; a portable computer, such as a hybrid computer, laptop computer, or tablet computer; a display, such as a computer monitor, television, or video conferencing equipment; a home appliance; or another electronic device of aesthetic interest, such as an automotive infotainment system.

[0024] In some embodiments, the body panel is a display cover on the display of an electronic device. For example, the body panel may be glass, tempered glass, acrylic, or other transparent panel materials. In embodiments of an electronic device with a display cover, segmented boundary portions reduce forces on the glass or other transparent material to limit and / or prevent breakage or damage to the display cover. For example, a glass display cover may break under compressive forces, or stresses from compressive forces may make the glass display cover more prone to breakage or damage during transport or use of the electronic device, even if the display cover does not break immediately after manufacturing. In some embodiments, the body panel is a metal, such as aluminum, magnesium, iron, titanium, or an alloy including such metals. In embodiments of an electronic device with a metal body panel having boundary portions applied thereto, compressive forces from the cooling and / or solidification of the material at the boundary portions may cause cracks, bending, or other deformations in the metal body panel.

[0025] Some embodiments of the electronic devices according to this disclosure have a main panel having a boundary portion positioned around the entire outer edge of the main panel. For example, a television may have a boundary portion positioned around the entire outer edge of the display glass. Figure 3 This is a front view of an electronic device 300 having a complete boundary portion 306. In some embodiments, the plate has a planar portion 304 defining a majority of a first surface, and the boundary portion 306 is positioned around the entire outer edge 310 of the planar portion 304. The display cover of the planar portion experiences greater stress compared to the boundary portion according to this disclosure due to being manufactured with a conventional boundary portion.

[0026] In some embodiments, the body panel has a boundary portion applied to a portion of the outer edge. Figure 4 This is a front view of an electronic device 400 having a partial boundary portion 406. In some embodiments, the electronic device 400 (such as a television remote control) has a display glass or other flat portion 404 positioned on the upper part of the top surface of the remote control, wherein a physical button is located on the lower part of the top surface, and a boundary portion 406 may be applied around three sides of the outer edge 410 of the flat portion 404, wherein no boundary portion 406 is close to the lower part containing the button.

[0027] In some embodiments, the boundary portion includes a second material different from a first material of the planar body panel. In some embodiments, the second material includes a polymer. In some embodiments, the second material includes a polymer with glass filler, such as D251 (20% glass filler), D151 (10% glass filler), or D551 (50% glass filler) available from SABIC Plastics. The second material is positioned at the outer edge of the body panel and is composed of a first plurality of segments and a second plurality of segments joined together at seams therebetween. In some embodiments, each of the second plurality of segments is inserted between adjacent segments of the first plurality of segments. In some embodiments, at least one segment of the boundary portion includes a third material different from the second material. The third material may provide material properties different from or additional to the second material.

[0028] Now for reference Figure 5 According to some embodiments of the electronic device 500 of this disclosure, a segmented boundary portion 506 is provided. In some embodiments, the segmented boundary portion 506 is formed in two stages, wherein a first plurality of segments 512-1 are first formed, and a second plurality of segments 512-2 are positioned in the space between the segments of the first plurality of segments 512-1. The first plurality of segments 512-1 and the second plurality of segments 512-2 are joined at a seam 514 at the lateral edges of the segments by adhesion and / or mechanical locking of the segments.

[0029] In some embodiments, the second material has higher strength than the third material, and the third material is positioned at a corner of the device to provide shock absorption. In some embodiments, the third material has greater radio permeability than the second material, and segments of the third material are positioned adjacent to and / or covering a radio frequency (RF) antenna of the electronic device such that the RF antenna can transmit and receive RF signals through an RF window created by the segment of the third material. For example, the second material may be D551 (a polycarbonate material with 50% glass fiber), and the third material may be D151 (a polycarbonate material with 10% glass fiber manufactured by Sabic).

[0030] In some embodiments (such as) Figure 5In the embodiments described herein, interlocking between the segments can provide additional strength to the joint 514. In some embodiments, the interlocking is a mechanical interlocking that inhibits movement of the first segment relative to the second segment at the joint 514. For example, the interlocking may include complementary structures that fit together to limit and / or prevent relative movement, such as protrusions and complementary recesses, wedge tenons and complementary pins, serrated patterns, irregular patterns, or other surface textures. In some embodiments, mechanical interlocking can limit and / or prevent relative movement in one direction transverse to the joint 514, such as wedge tenons. In some embodiments, mechanical interlocking can limit and / or prevent relative movement in two directions transverse to the joint 514, such as fully engaged posts. In some embodiments, the interlocking increases the surface area of ​​the joint 514, thereby providing a larger contact surface for the first and second segments to engage or adhere to each other.

[0031] In some embodiments, different materials in the boundary portion can provide additional or different functionality while maintaining the appearance of a single seamless boundary portion. For example, the boundary portion may include segments with a softer or more resilient material to allow for the inclusion of a physical button within the boundary portion. In some embodiments, the physical button (e.g., a button actuated by pressing a button) is located beneath the outer surface of the boundary portion, and the physical button can be actuated by elastically deforming a segment that contacts the physical button.

[0032] In some embodiments, the boundary portion may include segments configured to allow haptic feedback to be included in the boundary portion. In some embodiments, the segments are positioned to contact a motor or actuator (such as a linear actuator, a vibration motor, or a piezoelectric motor) that provides haptic feedback, and the segments transmit haptic information to the user.

[0033] In some embodiments, the boundary portion includes segments with conductive material to allow touch-sensitive controls embedded in or beneath the boundary portion. In some embodiments, a touch-sensitive button (e.g., a capacitive touch surface) is located below a segment on the outer surface of the boundary portion, and the touch-sensitive button can be activated by a user touching or pressing the segment.

[0034] The boundary portion can have a continuous or discontinuous profile. Now refer to... Figure 6 In some embodiments, the outer surface 616 of at least one segment of the boundary portion 606 is continuous with the outer surface 616 of the planar portion 604, such that the outer surface 616 of the segment provides the appearance of a continuous surface with the planar portion 604, wherein the segment contacts the outer edge 610 of the planar portion 604. In some embodiments, the outer surface of at least one segment of the boundary portion is discontinuous with the outer surface of the planar portion, such that the outer surface of the segment is oriented at a different angle from the planar portion, wherein the segment contacts the outer edge of the planar portion.

[0035] In some embodiments, at least one segment of the boundary portion 606 has a curved edge profile. In some embodiments, the curved profile has a constant radius of curvature, such as Figure 6 As explained in the text. In some embodiments, the curved profile has a decreasing radius of curvature away from the planar portion. In some embodiments, the curved profile has an increasing radius of curvature away from the planar portion. In some embodiments, at least one segment of the boundary portion has a discontinuous profile, such as a beveled or chamfered profile.

[0036] The segmented boundary portions are applied to the planar body panel in at least two stages. In some embodiments, a method 718 of manufacturing an electronic device includes: obtaining (720) a planar or substantially planar body panel comprising a first material; and applying (722) a first plurality of segments to the outer edges of the body panel. In some embodiments, the first plurality of segments comprises a second material different from the first material. For example, the first material may be glass, while the second material may be a polymer.

[0037] In some embodiments, the second material facilitates injection molding or another application of the second material at elevated temperatures. In some embodiments, a mask is positioned near and / or adjacent to the outer edge of the body panel, and a first injection of the second material is molded into the outer edge of the region surrounding and adjacent to the mask, such that when the mask is removed, the lateral edges of the first plurality of segments are defined by the mask shape.

[0038] The method further includes applying (724) a second plurality of segments to the outer edge of the body panel. In some embodiments, the second plurality of segments are positioned in the space between segments of the first plurality of segments. In some embodiments, each segment of the second plurality of segments contacts at least one of the segments of the first plurality of segments at its lateral edge to form a seam therebetween. In some embodiments, the second plurality of segments fill the space between segments of the first plurality of segments, and the first plurality of segments and the second plurality of segments create a continuous boundary portion.

[0039] In some embodiments, the boundary portion is positioned around the entire outer edge of the body panel. In some embodiments, the boundary portion is positioned on a portion smaller than the entire outer edge of the body panel. In some embodiments, the boundary portion is smaller than 90% of the entire outer edge of the body panel. In some embodiments, the boundary portion is smaller than 75% of the entire outer edge of the body panel. In some embodiments, the boundary portion is smaller than 50% of the entire outer edge of the body panel.

[0040] Figure 8 and 9 Explained about Figure 7 The application process of method 718 is described in two stages. Figure 8 The main panel includes a planar portion 804 and a boundary portion having only the first plurality of segments 812-1. The first plurality of segments 812-1 are applied to the outer edge 810 of the planar portion 804. Each segment of the first plurality of segments 812-1 is formed by masking the regions between the segments, and when the mask is removed, the first plurality of segments 812-1 and the space 826 therebetween are left.

[0041] Figure 9 The diagram shows a complete boundary portion 806 having an outer edge 810 surrounding the planar portion 804. Figure 8 The main panel. In some embodiments, a first plurality of segments 812-1 and a second plurality of segments 812-2 are positioned on equal lengths of the outer edge 810 of the planar portion 804. In some embodiments, the first plurality of segments 812-1 and the second plurality of segments 812-2 are positioned on different lengths of the outer edge 810 of the planar portion 804. In some embodiments, the first plurality of segments 812-1 are positioned on less than 90% of the outer edge 810 of the planar portion 804. In some embodiments, the first plurality of segments 812-1 are positioned on less than 75% of the outer edge 810 of the planar portion 804. In some embodiments, the first plurality of segments 812-1 are positioned on less than 50% of the outer edge 810 of the planar portion 804.

[0042] In some embodiments, when the boundary portion is positioned on the entire outer edge of the body panel, the first plurality of segments and the second plurality of segments are positioned at equal lengths of the boundary portion. In some embodiments, when the boundary portion is positioned on the entire outer edge of the body panel, the first plurality of segments and the second plurality of segments are positioned at different lengths of the boundary portion. In some embodiments, the first plurality of segments are positioned on less than 90% of the boundary portion. In some embodiments, the first plurality of segments are positioned on less than 75% of the boundary portion. In some embodiments, the first plurality of segments are positioned on less than 50% of the boundary portion. In some embodiments, the second plurality of segments fill the space between the first plurality of segments. For example, when the first plurality of segments are positioned along 90% of the boundary portion, the second plurality of segments are positioned along 10% of the boundary portion.

[0043] In some embodiments, the first plurality of segments shrink due to cooling from the elevated application temperature to ambient temperature and / or due to the second material curing over time. Therefore, by allowing the first plurality of segments to cool and shrink before applying the second plurality of segments, the compressive force on the body panel associated with the shrinkage of the second material can be reduced. The compressive force can be reduced proportionally to the length ratio of the first plurality of segments (which are shrinking) before applying the second plurality of segments. In some embodiments, a 1:1 ratio of the boundary lengths of the first plurality of segments to the second plurality of segments reduces the compressive force on the body panel by approximately 50%.

[0044] In some embodiments, the method further includes allowing the first plurality of segments to cool from a first temperature to a second temperature before applying the second plurality of segments. In some embodiments, the first temperature is the injection temperature of the second material when it is molded around a mask, and the second temperature is below 130°C. In some embodiments, the first temperature is the injection temperature of the second material when it is molded around a mask, and the second temperature is below 90°C.

[0045] In some embodiments, adhesion and / or mechanical locking of the segments from the boundary portion 806 to the outer edge 810 can be improved by applying a primer or etching the outer edge 810 of the planar portion 804 prior to the application of the second material. In some embodiments, the method includes altering the outer edge 810 to increase the surface area. In some embodiments, the outer edge 810 is chemically etched to increase surface embossing, and thus increases the surface area of ​​the outer edge 810. In some embodiments, the outer edge 810 is mechanically etched to increase surface embossing, and thus increases the surface area of ​​the outer edge 810. In some embodiments, the outer edge 810 is laser etched to increase surface embossing, and thus increases the surface area of ​​the outer edge 810. In some embodiments, the outer edge 810 is ion-etched or plasma-treated to increase surface embossing, and thus increases the surface area of ​​the outer edge 810.

[0046] In some embodiments, adhesion or interlocking between the segments of the first plurality of segments 812-1 and the segments of the second plurality of segments 812-2 can be improved by preparing lateral surfaces at the joint 814. In some embodiments, the lateral surfaces are primed in a manner similar to that of outer edges. In some embodiments, the lateral surfaces are primed in a different manner. In some embodiments, the lateral surfaces are chemically etched to increase surface relief and thus increase the surface area of ​​the lateral surfaces. In some embodiments, the lateral surfaces are mechanically etched to increase surface relief and thus increase the surface area of ​​the lateral surfaces. In some embodiments, the lateral surfaces are laser etched to increase surface relief and thus increase the surface area of ​​the lateral surfaces. In some embodiments, the lateral surfaces are ion etched to increase surface relief and thus increase the surface area of ​​the lateral surfaces.

[0047] In some embodiments where the second plurality of segments do not completely fill the space between the segments of the first plurality of segments, the method further includes applying at least one additional segment. In some embodiments, the at least one additional segment is a third plurality of segments. In some embodiments, the at least one additional segment is a single segment of a third material (such as a transmissive material) different from the second material to create an RF window in the boundary portion. In some embodiments, the at least one additional segment includes corner segments and a third material having greater elasticity than the second material to provide damping at the corners of the electronic device.

[0048] Industrial applicability

[0049] This disclosure generally relates to systems and methods for providing a body panel of an electronic device having a curved boundary portion. More specifically, this disclosure relates to a body panel comprising a first material connected to a boundary portion comprising a second material different from the first material. The boundary portion is formed in segments during assembly and applied to the first material to alleviate stresses in the first and second materials associated with the shrinkage of the second material, which is related to the cooling and / or curing of the second material.

[0050] In some embodiments, an electronic device has at least one substantially planar body panel that includes a portion of a first surface of the device. In some embodiments, the body panel includes a large portion of the first surface of the device. In some embodiments, the electronic device has a complementary second body panel that is substantially planar and includes a portion of a second surface of the device. In some embodiments, the electronic device has a complementary second body panel that is substantially planar and includes a large portion of the second surface of the device. In some embodiments, the first body panel and the second body panel are parallel to each other. In some embodiments, the first surface is a top surface and the second surface is a bottom surface. In some embodiments, the first surface is a front surface and the second surface is a rear surface.

[0051] In some embodiments, a portion or a majority of the body panel forming the first surface is completely planar. In some embodiments, the body panel is substantially planar because at least 90% of the surface of the body panel lies in a single plane or deviates from that plane by 10%. In some embodiments, the first surface of the electronic device is completely planar. In some embodiments, the first surface of the electronic device has non-planar portions, such as a keyboard, trackball, touchpad, other physical input mechanisms, textured grips, other raised or recessed portions, or other continuous or discontinuous areas that are not coplanar with the planar portions of the first surface.

[0052] In portable electronic devices, the device is typically held in the user's hand. A curved side of the electronic device provides a more comfortable grip. Flat body panels can be significantly cheaper and easier to manufacture than curved body panels. In some embodiments, attaching a flat body panel to the boundary portion of another part of the electronic device housing (e.g., a side panel, a complementary second body panel, or a barrel containing electronic components) can reduce costs, simplify assembly, allow for additional product design options, or combinations thereof. In some embodiments, attaching a flat body panel to the boundary portion of another part of the electronic device housing can visually blend the boundary portion with the flat portion, giving the flat portion a curved appearance to the user.

[0053] In conventional electronic devices, continuous boundary portions can exert compressive or shear forces on the body panel because the material of the boundary portion shrinks due to the cooling or curing of a secondary material over time. The segmented boundary portions according to this disclosure reduce the forces applied to the body panel, thereby allowing the use of larger areas and / or thinner body panels. In some embodiments, the boundary portion is applied to the outer edge of the body panel. In some embodiments, the boundary portion is secondary-molded onto the body panel. In some embodiments, at least a portion of the boundary portion is applied to a planar surface of the body panel. In some embodiments, the boundary portion is positioned around the complete outer edge (i.e., perimeter) of the body panel. In some embodiments, the boundary portion is positioned around a portion smaller than the complete outer edge of the body panel.

[0054] In some embodiments, the electronic device is a mobile electronic device, such as a smartphone or personal media device; a portable computer, such as a hybrid computer, laptop computer, or tablet computer; a display, such as a computer monitor, television, or video conferencing equipment; a home appliance; or another electronic device of aesthetic interest, such as an automotive infotainment system.

[0055] In some embodiments, the body panel is a display cover on the display of an electronic device. For example, the body panel may be glass, tempered glass, acrylic, or other transparent panel materials. In embodiments of an electronic device with a display cover, segmented boundary portions reduce forces on the glass or other transparent material to limit and / or prevent breakage or damage to the display cover. For example, a glass display cover may break under compressive forces, or stresses from compressive forces may make the glass display cover more prone to breakage or damage during transport or use of the electronic device, even if the display cover does not break immediately after manufacturing. In some embodiments, the body panel is a metal, such as aluminum, magnesium, iron, titanium, or an alloy including such metals. In embodiments of an electronic device with a metal body panel having boundary portions applied thereto, compressive forces originating from the cooling and / or solidification of the material at the boundary portions may cause cracking, bending, or other deformation of the metal body panel if it is thin (e.g., less than 1.0 mm thick, less than 0.8 mm thick, or less than 0.6 mm thick).

[0056] Some embodiments of the electronic devices according to this disclosure have a main panel having a boundary portion positioned around the entire outer edge of the main panel. For example, a television may have a boundary portion positioned around the entire outer edge of a display glass. In some embodiments, the main panel has a boundary portion applied to a portion of the outer edge. For example, a television remote control may have a display glass positioned on the upper part of the top surface of the remote control, with physical buttons located on the lower part of the top surface, and the boundary portion may be applied around three sides of the display glass, with no boundary portion adjacent to the lower part containing the buttons.

[0057] In some embodiments, the boundary portion includes a second material different from a first material of the planar body panel. In some embodiments, the second material includes a polymer. In some embodiments, the second material includes a polymer with glass filler, such as D251 (20% glass filler), D151 (10% glass filler), or D551 (50% glass filler) available from SABIC Plastics. The second material is positioned at the outer edge of the body panel and is composed of a first plurality of segments and a second plurality of segments joined together at seams therebetween. In some embodiments, each of the second plurality of segments is inserted between adjacent segments of the first plurality of segments. In some embodiments, at least one segment of the boundary portion includes a third material different from the second material. The third material may provide material properties different from or additional to the second material.

[0058] In some embodiments, the second material has higher strength than the third material, and the third material is positioned at a corner of the device to provide shock absorption. In some embodiments, the third material has greater radiometric permeability than the second material, and segments of the third material are positioned adjacent to and / or covering the RF antenna of the electronic device such that the RF antenna can transmit and receive RF signals through an RF window created by the segment of the third material. For example, the second material could be D551, and the third material could be D151.

[0059] Interlocking between segments can provide additional strength to the joint between the segments. In some embodiments, the interlocking is a mechanical interlocking that prevents movement of the first segment relative to the second segment at the joint. For example, the interlocking may include complementary structures that fit together to limit and / or prevent relative movement, such as protrusions and complementary recesses, wedge tenons and complementary pins, serrated patterns, irregular patterns, or other surface textures. In some embodiments, mechanical interlocking can limit and / or prevent relative movement in one direction transverse to the joint, such as wedge tenons. In some embodiments, mechanical interlocking can limit and / or prevent relative movement in two directions transverse to the joint, such as fully engaged posts. In some embodiments, the interlocking increases the surface area of ​​the joint, thereby providing a larger contact surface for the first and second segments to engage or adhere to each other.

[0060] In some embodiments, different materials in the boundary portion can provide additional or different functionality while maintaining the appearance of a single seamless boundary portion. For example, the boundary portion may include segments with a softer or more resilient material to allow for the inclusion of a physical button within the boundary portion. In some embodiments, the physical button (e.g., a button actuated by pressing a button) is located beneath the outer surface of the boundary portion, and the physical button can be actuated by elastically deforming a segment that contacts the physical button.

[0061] In some embodiments, the boundary portion may include segments of a softer or more flexible material to allow tactile feedback to be included in the boundary portion. In some embodiments, the segments are positioned to contact a motor or actuator (such as a linear actuator, a vibration motor, or a piezoelectric motor) that provides tactile feedback, and the segments transmit tactile information to the user.

[0062] In some embodiments, the boundary portion includes segments with conductive material to allow touch-sensitive controls embedded in or beneath the boundary portion. In some embodiments, a touch-sensitive button (e.g., a capacitive touch surface) is located beneath the outer surface of the boundary portion, and the physical button is actuated by touching a segment of the physical button.

[0063] The boundary portion may have a continuous or discontinuous profile. In some embodiments, the outer surface of at least one segment of the boundary portion is continuous with the outer surface of the planar portion, such that the outer surface of the segment provides the appearance of a continuous surface with the planar portion, wherein the segment contacts the outer edge of the planar portion. In some embodiments, the outer surface of at least one segment of the boundary portion is discontinuous with the outer surface of the planar portion, such that the outer surface of the segment is oriented at a different angle from the planar portion, wherein the segment contacts the outer edge of the planar portion.

[0064] In some embodiments, at least one segment of the boundary portion has a curved edge profile. In some embodiments, the curved profile has a constant radius of curvature. In some embodiments, the curved profile has a decreasing radius of curvature away from the planar portion. In some embodiments, the curved profile has an increasing radius of curvature away from the planar portion. In some embodiments, at least one segment of the boundary portion has a discontinuous profile, such as a beveled or chamfered profile.

[0065] The segmented boundary portions are applied to the planar body panel in at least two stages. In some embodiments, a method of manufacturing an electronic device includes: obtaining a planar or substantially planar body panel comprising a first material; and applying a first plurality of segments to the outer edges of the body panel. In some embodiments, the first plurality of segments comprises a second material different from the first material. For example, the first material may be glass, while the second material may be a polymer.

[0066] In some embodiments, the second material facilitates injection molding or another application of the second material at elevated temperatures. In some embodiments, a mask is positioned near and / or adjacent to the outer edge of the body panel, and a first injection of the second material is molded into the outer edge of the region surrounding and adjacent to the mask, such that when the mask is removed, the lateral edges of the first plurality of segments are defined by the mask shape.

[0067] The method further includes applying a second plurality of segments to the outer edge of the body panel. In some embodiments, the second plurality of segments are positioned in the space between segments of the first plurality of segments. In some embodiments, each segment of the second plurality of segments contacts at least one of the segments of the first plurality of segments at its lateral edge to form a seam therebetween. In some embodiments, the second plurality of segments fill the space between segments of the first plurality of segments, and the first plurality of segments and the second plurality of segments create a continuous boundary portion.

[0068] In some embodiments, the boundary portion is positioned around the entire outer edge of the body panel. In some embodiments, the boundary portion is positioned on a portion smaller than the entire outer edge of the body panel. In some embodiments, the boundary portion is smaller than 90% of the entire outer edge of the body panel. In some embodiments, the boundary portion is smaller than 75% of the entire outer edge of the body panel. In some embodiments, the boundary portion is smaller than 50% of the entire outer edge of the body panel.

[0069] In some embodiments, the first plurality of segments and the second plurality of segments are positioned at equal lengths along the outer edge of the main body panel. In some embodiments, the first plurality of segments and the second plurality of segments are positioned at different lengths along the outer edge of the main body panel. In some embodiments, the first plurality of segments are positioned along less than 90% of the outer edge of the main body panel. In some embodiments, the first plurality of segments are positioned along less than 75% of the outer edge of the main body panel. In some embodiments, the first plurality of segments are positioned along less than 50% of the outer edge of the main body panel.

[0070] In some embodiments, when the boundary portion is positioned on the entire outer edge of the body panel, the first plurality of segments and the second plurality of segments are positioned at equal lengths of the boundary portion. In some embodiments, when the boundary portion is positioned on the entire outer edge of the body panel, the first plurality of segments and the second plurality of segments are positioned at different lengths of the boundary portion. In some embodiments, the first plurality of segments are positioned on less than 90% of the boundary portion. In some embodiments, the first plurality of segments are positioned on less than 75% of the boundary portion. In some embodiments, the first plurality of segments are positioned on less than 50% of the boundary portion. In some embodiments, the second plurality of segments fill the space between the first plurality of segments. For example, when the first plurality of segments are positioned along 90% of the boundary portion, the second plurality of segments are positioned along 10% of the boundary portion.

[0071] In some embodiments, the first plurality of segments shrink due to cooling from the elevated application temperature to ambient temperature and / or due to the second material curing over time. Therefore, by allowing the first plurality of segments to cool and shrink before applying the second plurality of segments, the compressive force on the body panel associated with the shrinkage of the second material can be reduced. The compressive force can be reduced proportionally to the ratio of the length of the first plurality of segments (which are shrinking) before applying the second plurality of segments. In some embodiments, a 1:1 ratio of the boundary lengths of the first plurality of segments to the second plurality of segments reduces the compressive force on the body panel by approximately 50%.

[0072] In some embodiments, the method further includes allowing the first plurality of segments to cool from a first temperature to a second temperature before applying the second plurality of segments. In some embodiments, the first temperature is the injection temperature of the second material when it is molded around a mask, and the second temperature is below 130°C. In some embodiments, the first temperature is the injection temperature of the second material when it is molded around a mask, and the second temperature is below 90°C.

[0073] In some embodiments, adhesion and / or mechanical locking of the boundary portion to the segments of the outer edge can be improved by applying a primer or etching the outer edge of the body panel prior to the application of the second material. In some embodiments, the method includes altering the outer edge to increase the surface area. In some embodiments, the outer edge is chemically etched to increase surface embossing, and thus increases the surface area of ​​the outer edge. In some embodiments, the outer edge is mechanically etched to increase surface embossing, and thus increases the surface area of ​​the outer edge. In some embodiments, the outer edge is laser etched to increase surface embossing, and thus increases the surface area of ​​the outer edge. In some embodiments, the outer edge is ion-etched or plasma-treated to increase surface embossing, and thus increases the surface area of ​​the outer edge.

[0074] In some embodiments, adhesion or interlocking between the segments of the first plurality of segments and the segments of the second plurality of segments can be improved by preparing lateral surfaces at the joints. In some embodiments, the lateral surfaces are primed in a manner similar to that of the outer edges. In some embodiments, the lateral surfaces are primed in a different manner. In some embodiments, the lateral surfaces are chemically etched to increase surface relief and thus increase the surface area of ​​the lateral surfaces. In some embodiments, the lateral surfaces are mechanically etched to increase surface relief and thus increase the surface area of ​​the lateral surfaces. In some embodiments, the lateral surfaces are laser etched to increase surface relief and thus increase the surface area of ​​the lateral surfaces. In some embodiments, the lateral surfaces are ion etched to increase surface relief and thus increase the surface area of ​​the lateral surfaces.

[0075] In some embodiments where the second plurality of segments do not completely fill the space between the segments of the first plurality of segments, the method further includes applying at least one additional segment. In some embodiments, the at least one additional segment is a third plurality of segments. In some embodiments, the at least one additional segment is a single segment of a third material (such as a transmissive material) different from the second material to create an RF window in the boundary portion. In some embodiments, the at least one additional segment includes corner segments and a third material having greater elasticity than the second material to provide damping at the corners of the electronic device.

[0076] This disclosure describes electronic devices and methods for manufacturing them, which offer improved aesthetics and comfort while enabling the use of larger body panels with increased durability and / or portability. This disclosure relates to systems and methods for providing body panels of electronic devices having segmented boundary portions, according to examples provided at least in the following sections:

[0077] 1. An electronic device (e.g., 100), comprising:

[0078] A display cover (e.g., 102) includes a glass planar portion (e.g., 104) comprising a first material and a second material positioned at the outer edge (e.g., 310) of the glass planar portion, wherein:

[0079] The glass plane portion defines most of the display surface, and

[0080] A second material is molded to the outer edge of the glass planar portion and defines at least a portion of the boundary portion (e.g., 606) that is bent in a direction perpendicular to the display surface (e.g., outer surface 616), wherein the second material is composed of a first plurality of segments (e.g., 512-1) and a second plurality of segments (e.g., 512-2), wherein each of the second plurality of segments is inserted between adjacent segments of the first plurality of segments, and wherein the first plurality of segments interlock with the second plurality of segments (e.g., seam 514).

[0081] 2. The electronic device as described in section 1, wherein the material composition of the first plurality of segments is different from the material composition of the second plurality of segments.

[0082] 3. An electronic device as described in section 1 or 2, wherein each of the first plurality of segments and the second plurality of segments includes one or more interlocking features to facilitate interlocking of the first plurality of segments with the second plurality of segments.

[0083] 4. The electronic device as described in any of the preceding sections, wherein the display is a touch-sensitive display.

[0084] 5. The electronic device as described in section 4, wherein the touch-sensitive area of ​​the touch-sensitive display includes at least a portion of the boundary portion.

[0085] 6. An electronic device as described in any of the preceding sections, wherein at least one segment of the second material is coupled to the electronic circuitry of the electronic device and is configured to provide physical button functionality.

[0086] 7. The electronic device as described in any of the preceding sections further includes: a radio frequency antenna, wherein at least one segment of the second material is a transmittance line, and wherein the antenna is located in the vicinity of the transmittance line segment.

[0087] 8. The electronic device as described in any of the preceding sections further includes: a housing (e.g., a metal body panel 108), wherein a second material is attached to the glass planar portion of the housing.

[0088] 9. A method of manufacturing a display as described in section 1, the method comprising:

[0089] (720) The flat portion of the glass is obtained;

[0090] The first plurality of segments are applied (722) to the outer edge of the glass planar portion, the first plurality of segments having spaces positioned between adjacent segments; and

[0091] After the first plurality of segments are applied, the second plurality of segments are applied (724) to the outer edge, the second plurality of segments being positioned in the space between the segments of the first plurality of segments, wherein the first plurality of segments and the second plurality of segments form the boundary portion of the display.

[0092] 10. The method of section 9, wherein applying the first plurality of segments includes applying the first plurality of segments at a first temperature; and

[0093] The method further includes: allowing the first plurality of segments to cool to a second temperature before applying the second plurality of segments, wherein the first plurality of segments shrink when cooled to the second temperature, and wherein each segment of the second plurality of segments is resized to interlock with the first plurality of segments after shrinkage.

[0094] 11. The method as described in section 9 or 10, further comprising: altering the outer edge of the glass panel before applying the first plurality of segments.

[0095] 12. The method of any of sections 9-11, further comprising: altering the lateral edges of the first plurality of segments before applying the second plurality of segments.

[0096] 13. A main panel of an electronic device, comprising:

[0097] Includes a planar portion of a first material (e.g., 804), wherein the planar portion has an outer edge (e.g., 810).

[0098] At least a portion of the outer edge of the planar portion is connected to a boundary portion (e.g., 806) of the planar portion, the boundary portion being made of a second material different from the first material, wherein the boundary portion includes:

[0099] The first plurality of segments directly connected to the outer edge (e.g., 812-1), and

[0100] A second plurality of segments (e.g., 812-2) are directly connected to the outer edge, wherein each of the second plurality of segments is inserted between the segments of the first plurality of segments, and wherein each of the second plurality of segments contacts the adjacent segment of the first plurality of segments at a corresponding seam (e.g., 814).

[0101] 14. The main panel of section 13, wherein the primary material is glass.

[0102] 15. The main panel as described in section 13 or 14, wherein the second material is a polymer.

[0103] 16. The main panel of any of sections 13-15, wherein each seam includes interlocking in the corresponding segment.

[0104] 17. The main panel of any of sections 13-16, wherein the second plurality of segments are transmissive.

[0105] 18. The main panel of any of sections 13-17, wherein the seam is waterproof.

[0106] 19. The main panel of any of sections 13-18, wherein the boundary portion is curved in a direction normal to the surface plane of the planar portion.

[0107] 20. The main panel of any of sections 13-19, wherein the planar portion has a curved region near at least a portion of the outer edge.

[0108] 21. The main panel of any of sections 13-20, wherein the boundary portion is asymmetrical.

[0109] 22. The main panel of any of sections 13-21, wherein the boundary portion is positioned around the entire outer edge.

[0110] 23. The main panel of any of sections 13-22, wherein the first material is metal.

[0111] 24. The main panel of section 23, wherein the thickness of the metal is less than 0.6 mm.

[0112] 25. The main panel of any of sections 13-24, wherein the boundary portion is conductive.

[0113] 26. The main panel of any of sections 13-25, wherein the boundary portion is configured to visually blend with the planar portion and give the planar portion a curved appearance.

[0114] The articles “a,” “an,” and “the” are intended to indicate that one or more of the elements are present in the foregoing description. The terms “comprising,” “including,” and “having” are intended to be inclusive and indicate that additional elements may be present in addition to those listed. Additionally, it will be understood that references to “one embodiment” or “an embodiment” in this disclosure are not intended to be construed as excluding the existence of additional embodiments that also incorporate the described features. For example, any element described in relation to an embodiment herein may be combined with any element of any other embodiment described herein. Numbers, percentages, ratios, or other values ​​set forth herein are intended to include such values, as well as other values ​​approximately or approximating the set forth values, as will be appreciated by those skilled in the art as covered by embodiments of this disclosure. Therefore, the set forth values ​​should be interpreted broadly enough to cover values ​​that are at least sufficiently close to those used to perform the desired function or achieve the desired result. The set forth values ​​include at least the variations that would be anticipated in a suitable processing or production process and may include values ​​within 5%, 1%, 0.1%, or 0.01% of the set forth values.

[0115] In view of this disclosure, those skilled in the art will recognize that equivalent constructions do not depart from the spirit and scope of this disclosure, and that various changes, substitutions, and modifications can be made to the embodiments disclosed herein without departing from the spirit and scope of this disclosure. Equivalent constructions including the "device plus function" clause are intended to cover structures described herein as performing said function, including both structural equivalents operating in the same manner and equivalent structures providing the same function. The applicant's explicit intention is that no claim shall invoke a device plus function or other functional statement unless the term 'device for…' appears with the associated function. Every addition, deletion, and modification to the embodiments within the meaning and scope of the claims shall be accepted by the claims.

[0116] It should be understood that any direction or frame of reference described above is only a relative direction or movement. For example, any reference to “front” and “back” or “top” and “bottom” or “left” and “right” merely describes the relative position or movement of the relevant element.

[0117] This disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered illustrative rather than restrictive. Thus, the scope of the invention is indicated by the appended claims rather than the foregoing description. Changes falling within the meaning and scope of equivalents of the claims should be covered by the scope of the claims.

Claims

1. An electronic device, comprising: The display includes a glass planar portion and a boundary portion, the boundary portion being composed of at least two moldable materials positioned at the outer edge of the glass planar portion, wherein: The glass plane portion defines most of the display surface, and The boundary portion has been molded to the outer edge of the glass planar portion, and at least a portion of the boundary portion is curved in a direction perpendicular to the display surface. The boundary portion is composed of a first plurality of segments made of a second material that is different from the first material and a second plurality of segments made of a third material that is different from both the first and second materials. Each of the second plurality of segments is inserted between adjacent segments of the first plurality of segments, and the first plurality of segments are interlocked with the second plurality of segments.

2. The electronic device as claimed in claim 1, wherein, Each of the first plurality of segments and the second plurality of segments includes one or more interlocking features to facilitate interlocking between the first plurality of segments and the second plurality of segments.

3. The electronic device as claimed in any of the preceding claims, wherein, The display is a touch-sensitive display.

4. The electronic device as claimed in claim 3, wherein, The touch-sensitive area of ​​the touch-sensitive display includes at least a portion of the boundary portion.

5. The electronic device as claimed in any one of claims 1 or 2, wherein, The physical button is located in the boundary portion, or at least one segment of the second material is coupled to the electronic circuitry of the electronic device and configured to provide physical button functionality.

6. The electronic device as claimed in any one of claims 1 or 2, further comprising: A radio frequency antenna, wherein at least one segment of the second material is a transmission line segment, and wherein the radio frequency antenna is located near the transmission line segment.

7. The electronic device as claimed in any one of claims 1 or 2, further comprising: A housing, wherein the second material connects the glass planar portion to the housing.

8. A method of manufacturing the electronic device as claimed in claim 1, the method comprising: Obtain the glass planar portion; The first plurality of segments are applied to the outer edge of the glass plane portion, the first plurality of segments having space positioned between adjacent segments of the first plurality of segments; as well as After the first plurality of segments are applied, the second plurality of segments are applied to the outer edge, the second plurality of segments being positioned in the space between the segments of the first plurality of segments, wherein the first plurality of segments and the second plurality of segments form the boundary portion of the display.

9. The method of claim 8, wherein, Applying the first plurality of segments includes applying the first plurality of segments at a first temperature; as well as The method further includes: allowing the first plurality of segments to cool to a second temperature before applying the second plurality of segments, wherein the first plurality of segments shrink when cooled to the second temperature, and wherein each segment of the second plurality of segments is resized to interlock with the first plurality of segments after the shrinkage.

10. The method of claim 8 or 9, further comprising: The outer edge of the glass plane portion is changed before the first plurality of segments are applied.

11. The method of claim 8 or 9, further comprising: The lateral edges of the first plurality of segments are prepared before applying the second plurality of segments, wherein the lateral edges of the first plurality of segments are edges for direct connection with corresponding edges on the second plurality of segments.

12. A main panel of an electronic device, comprising: The planar main panel portion includes a first material, wherein the planar main panel portion has an outer edge. At least a portion of the outer edge of the planar body panel portion is connected to a boundary portion of the planar body panel portion, the boundary portion comprising a second material different from the first material, wherein the boundary portion includes segmented boundary portions, and the boundary portion has been molded to the planar body panel portion, and wherein the boundary portion comprises: The first plurality of segments directly connected to the outer edge, and A second plurality of segments directly connected to the outer edge, wherein the first plurality of segments and the second plurality of segments are connected to the outer edge in at least two stages, wherein each of the second plurality of segments is inserted between the segments of the first plurality of segments connected to the outer edge, and wherein each of the second plurality of segments contacts an adjacent segment of the first plurality of segments at a corresponding seam; and wherein at least one segment of the boundary portion comprises a third material different from the second material.

13. The main panel as claimed in claim 12, wherein, The first plurality of segments are interlocked with the second plurality of segments.

14. The main panel as claimed in claim 12 or 13, wherein, The first material is glass.

15. The main panel as claimed in claim 12 or 13, wherein, The second material is a polymer.

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