Patent Application
20080063927
There are presently shown in the drawings embodiments which are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
While the specification concludes with claims defining the features of the embodiments of the invention that are regarded as novel, it is believed that the devices and method, and other embodiments will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward.
As required, detailed embodiments of the present device and method are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the embodiments of the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the embodiments herein.
The terms “a” or “an,” as used herein, are defined as one or more than one. The phrase “at least one of” as used herein, is defined as one or more than one. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). As used in this application, the term “unitary” refers to structure that is a continuous whole unit without breaks or the fastening of two components. In contrast, a component that is created by coupling two separate components is a non-limiting example of a component that is not unitary. As also used in this application, the term “void” is a empty space through a structure. As also used in this application, the phrase “elastic modulus” refers to the measure of the stiffness of a given material. Further, the term “disposed” refers to the integration of one material, or component, with another through any suitable means of combing the same, including second shot molding, over molding and the like. Finally, the term “biased” or “biasing” refers to an arrangement of structure that creates a force in a particular direction.
The present invention provides a solution to the limitations of the prior art, which are becoming increasingly significant as mobile electronic devices are continuously trending to small and thinner devices. More specifically, the present invention provides for the replacement of parts that were previously mounted via screws, adhesives and the like and that could result in failures due to improper mounting or stress concentrations, with a section of a molding that is unitary with a large portion of the external molding. Unitary molding eliminates the problems associated with improperly placed separate parts and the ever increasing difficulty in arranging relatively small sized parts. Still further, a method of manufacturing mobile electronic devices to include such unitary molding is also provided.
By reference to the exemplary drawings in detail wherein like numerals indicate like elements throughout the various views, there is shown in
The first molding 110 provides a variety of internal support structures for various components of the electronic mobile device, such a subscriber identification module card holder, and has a periphery 210 that serves a base to which at least a portion of the second molding 140 is disposed. The first molding 110 can provide structural support to the overall housing 100, and thus, can be constructed of a material with a greater elastic modulus than other components of the housing 100, including the second molding 140. Non-limiting examples of such materials include thermoplastic materials, such as polystyrene or acrylonitrile butadiene styrene.
The first molding 110 provides the battery compartment 120, in which the battery is retained. Portions of the first molding 110 provide one or more walls 170 that define the battery compartment 120. The size of the battery compartment 120 can vary as needed dependent upon the battery to be housed and the overall size of the housing 100.
The first molding 110 also provides the internal cavity 130, which is an open volume of space adjacent to the wall 170 that the defines the battery compartment 120. The internal cavity 130 is shown in
Additionally, the first molding 110 can provide battery biasing protrusion support members 190 that extend at least partially across the internal cavity 130. These support members 190 can be constructed to be flexible to allow some bending at least away from the battery compartment 120.
The second molding 140 can be disposed on the first molding 110 in a variety of manners to provide at least a portion of the outer surface 200 of the electronic device housing 100. The second molding 140, including all of its various portions, can be a unitary construction of one member, obviating any need to join two or more pieces together. In addition to forming portions of the outer surface 200, the second molding 140 can fill internal cavity 130 with biasing protrusion base 150 and provide battery biasing protrusion 160. The second molding 140 can be formed of similar materials to those that form the first molding 110; however, the elastic modulus of the material of the second molding 140 can be less than the elastic modulus of the first molding 110, to provide an ability to deflect or to be compressed to a greater degree.
The biasing protrusion base 150 can be substantially flush with the wall 170 of the battery compartment 120. The base 150 can abut against, or have embedded therein, the support members 190 to resist forces pushing the base 150 away from the battery compartment 120. Nevertheless, the side of the base 150 that is opposite the battery compartment 120 is adjacent to void 180, and is thus an unsupported side of the base 150. This unsupported side of base 150 allows the base 150 to flex or deflect into the void 180, if needed.
The base 150 provides support for, and the surface from which, the battery biasing protrusion 160 protrudes towards the battery compartment 120. The protrusion 160 can be of any suitable size or shape for being engaged by the battery during and after insertion of the battery and ensuring that the battery is maintained in the battery compartment 120. With the battery inserted, the protrusion 160 is compressed in the direction towards the base 150 and the protrusion 160, the base 150, and even the support members 190 can be deflected or compressed away from the battery compartment 120.
There is shown in
The present invention also provides a method 400 of manufacturing a portable electronic device housing with a molding. The steps of the method are illustrated in a flow chart shown as
In step 410, a first molding of a first molding material is provided, where the first molding defines a battery compartment and an internal cavity, and further provides a void located at a side of the internal cavity opposite to the battery compartment. The first molding can be created during a two shot molding process; however, such a process is not necessary for completion of method 400. Method 400 contemplates both the creation of the first molding and starting method 400 with a preformed first molding.
In step 420, a second molding material can be disposed on the first molding at the periphery of the first molding. The disposing of the second molting material can occur at elevated temperatures and pressures to ensure proper distribution of the second molding material.
It should be noted that steps 410 and 420 can be combined by means of successive molding methods. With successive methods, the steps can include injection molding one part, transferring this part to a second mold as an insert, and molding the second component against the first. One example of such successive methods includes injecting molten plastic at an elevated pressure into a mold, which is the inverse of the desired shape.
In step 430, the internal cavity can be filled with the second molding material. Again, this step can be combined with steps 410 and 420 and can occur with the second molding material under pressure and at elevated temperature.
In step 440, a battery biasing protrusion that protrudes towards the battery compartment can be formed. This protrusion can be formed by placing the first molding in a second mold and introducing a thermoplastic into the open areas. The protrusion remains after the thermoplastic cools and the second mold is removed.
This invention can be embodied in other forms without departing from the spirit or essential attributes thereof. For instance, although the electronic device housing is shown as a mobile phone, one skilled in the art would readily recognize that the invention can be used with a wide variety of electronic devices, such as radios, personal digital assistants, micro computers, and the like. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope of the invention.
