U.S. patent application number 11/519285 was filed with the patent office on 2008-03-13 for machined window undercut.
Invention is credited to Pinida Jan Moolsintong, Douglas J. Weber, Stephen P. Zadesky.
Application Number | 20080063218 11/519285 |
Document ID | / |
Family ID | 39169724 |
Filed Date | 2008-03-13 |
United States Patent
Application |
20080063218 |
Kind Code |
A1 |
Weber; Douglas J. ; et
al. |
March 13, 2008 |
Machined window undercut
Abstract
A media player comprising a display screen is provided. The
media player can include a housing having an opening and an area of
reduced thickness around the opening. The media player can also
include a transparent wall having a flange. Alternatively, the
transparent wall may not require a flange but rather can be a flat,
substantially transparent piece of material such as plexiglass or
glass. The flange can be adhered to a surface of the area of
reduced thickness in order to form a transparent protective cover
for the display screen. In another embodiment of the invention, a
method is provided. The method can include forming a transparent
wall having a stepped edge for placing in an opening of a media
player. The method can also include adhering an adhesive to at
least one surface of the stepped edge of the transparent wall. The
method can include as well using the cutting tool to cut away a
portion of the underside of a housing that surrounds an opening in
a media player. The method can also include adhering the
transparent wall to the housing using the adhesive.
Inventors: |
Weber; Douglas J.; (Arcadia,
CA) ; Moolsintong; Pinida Jan; (St. Louis, MO)
; Zadesky; Stephen P.; (Portola Valley, CA) |
Correspondence
Address: |
ROPES & GRAY LLP;PATENT DOCKETING 39/361
1211 AVENUE OF THE AMERICAS
NEW YORK
NY
10036-8704
US
|
Family ID: |
39169724 |
Appl. No.: |
11/519285 |
Filed: |
September 11, 2006 |
Current U.S.
Class: |
381/87 ;
361/679.26 |
Current CPC
Class: |
Y10T 156/1066 20150115;
Y10T 156/1082 20150115; H05K 5/0239 20130101; Y10T 156/1059
20150115; H04R 1/02 20130101; Y10T 156/1062 20150115; H04R 5/00
20130101; Y10T 156/1064 20150115 |
Class at
Publication: |
381/87 ;
361/679 |
International
Class: |
H04R 1/02 20060101
H04R001/02; H05K 5/00 20060101 H05K005/00 |
Claims
1. A portable media player comprising: a display screen; a housing
having an opening and an area of reduced thickness around the
opening; and a transparent wall comprising a flange, the flange
that is adhered to a surface of the area of reduced thickness,
wherein the transparent wall a transparent protective cover for the
display screen.
2. The media player of claim 1 wherein the area of reduced
thickness is oriented internally to the media player.
3. The media player of claim 1 wherein the area of reduced
thickness is oriented externally to the media player.
4. The media player of claim 1 the housing comprising a stepped
edge around the opening.
5. The media player of claim 1 further comprising a closed-back
face.
6. The media player of claim 1 further comprising a hand-held media
player.
7. The media player of claim 1 further comprising a miniature media
player.
8. A method comprising: forming a housing for storing components of
a media player; forming an opening in one of the faces of the
housing; penetrating a cutting tool through the opening; and using
the cutting tool to cut away a portion of the underside of the
housing that surrounds the opening.
9. The method of claim 8 further comprising adhering a transparent
wall to the cut away portion of the underside of the housing.
10. The method of claim 8 further comprising adhering an adhesive
to a transparent wall, and then adhering the transparent wall to
the cut away portion of the underside of the housing using the
adhesive.
11. The method of claim 8 further comprising adhering an adhesive
to a cutout portion of the housing of the media player.
12. The method of claim 8 the forming a housing for storing
components of a media player further comprising forming a housing
for storing components of a miniature media player.
13. The method of claim 8 the forming a housing for storing
components of a media player further comprising forming a housing
for storing components of a hand-held media player.
14. A method for forming a housing of a media player, the method
comprising: forming a transparent wall having a stepped edge, the
transparent wall for placing in an opening of a media player;
adhering an adhesive to at least one surface of the stepped edge of
the transparent wall; using the cutting tool to cut away a portion
of the underside of a housing that surrounds an opening in a media
player; and adhering the transparent wall to the housing using the
adhesive.
15. The method of claim 14 further comprising adhering the adhesive
to a plurality of surfaces of the transparent wall.
16. The method of claim 14 further comprising placing the
transparent wall through one end in the housing, the one end in the
housing being different from the opening in the housing.
17. The method of claim 14 further comprising using the cutting
tool to cut away a portion of the underside of a housing that
surrounds an opening in a miniature media player.
18. The method of claim 14 further comprising using the cutting
tool to cut away a portion of the underside of a housing that
surrounds an opening in a hand-held media player.
19. A media player housing comprising an opening for disposing a
window therein, the opening being substantially bound by a
perimeter area of the housing, the perimeter area having a
thickness less than a majority of the housing.
20. The media player housing of claim 19 wherein the perimeter area
is oriented internally to the media player.
21. The media player housing of claim 19 wherein the perimeter area
is oriented externally to the media player.
22. The media player housing of claim 19 the housing comprising a
stepped edge around the opening.
23. The media player housing of claim 19 further comprising a
closed-back face.
24. The media player housing of claim 1 further comprising a
hand-held media player housing.
25. The media player housing of claim 1 further comprising a
miniature media player housing.
26. A media player comprising: a display screen; a housing having
an opening and an area of reduced thickness around the opening, the
dimension of corners of the area of reduced thickness in the x-axis
and the dimension of the corner of the opening in the y-axis each
being determined by the radius of a shaft and the radius of a
cutting head of a cutter used for obtaining the area of reduced
thickness; and a transparent wall comprising a flange, the flange
that is adhered to a surface of the area of reduced thickness.
27. The media player of claim 26 wherein the area of reduced
thickness faces internally to the media player.
28. The media player of claim 26 wherein the area of reduced
thickness faces externally to the media player.
29. The media player of claim 26 the housing further comprising a
stepped edge around the opening.
30. The media player of claim 26 further comprising a closed-back
face.
31. The media player of claim 26 further comprising a hand-held
media player.
32. The media player of claim 26 further comprising a miniature
media player.
33. A method for forming the housing of media player, the method
comprising: forming a housing for storing components of a media
player; forming an opening in one of the faces of the housing;
penetrating a cutting tool through the opening, the cutting tool
comprising a circular cutting head; and using the cutting tool to
reduce the thickness of a portion of the underside of the housing
that surrounds the opening, the portion of the underside comprising
corners, dimensions of the corners in the x-axis and the y-axis
being substantially dependent upon the radius of the head of the
cutting tool.
34. The method of claim 33 further comprising adhering a
transparent wall to the cut away portion of the underside of the
housing, dimensions of the corners of the transparent wall being
substantially dependent upon the dimensions of the corners of the
reduced thickness portion of the underside of the housing.
35. The method of claim 33 further comprising adhering an adhesive
to a transparent wall, and then adhering the transparent wall to
the reduced thickness portion of the underside of the housing using
the adhesive.
36. The method of claim 33 further comprising adhering an adhesive
to the reduced thickness portion of the housing of the media
player.
37. The method of claim 33 the forming a housing for storing
components of a media player further comprising forming a housing
for storing components of a hand-held media player.
38. The method of claim 33 the forming a housing for storing
components of a media player further comprising forming a housing
for storing components of a miniature media player.
39. The method of claim 33 the forming a housing for storing
components of a media player further comprising m a housing for
storing components of a miniature media player.
40. A method for forming a media player housing, the method
comprising: molding the housing, wherein the housing comprises an
opening for disposing a window therein; and molding the a perimeter
region of the housing around the opening, the perimeter region
having a thickness less than a majority of the housing.
Description
BACKGROUND OF THE INVENTION
[0001] This invention can relate to methods that improve
construction of electronic devices. More specifically, this
invention can relate to improving the efficiency of an electronic
device stored in a closed-back housing.
[0002] As products compete to be thinner and thinner, it is
important to be as space efficient as possible both to make room
for other components as well as to improve and ease the assembly
process as much as possible.
[0003] In conventional closed-back products, the window normally
sits flat on the interior of the housing surface, so no space is
saved. More specifically, the window flange simply sits on top of
the housing's inner surface.
[0004] Therefore, it would be desirable to increase the volume
available for storing components in an electronic device without
increasing the device size.
[0005] It would also be desirable to increase the volume available
for components in a closed-back electronic device.
[0006] It would be yet further desirable to increase the volume
available for storing electronic components in an electronic device
while substantially maintaining the structural integrity of the
device and attendant level of protection provided to the
components.
SUMMARY OF THE INVENTION
[0007] A trend exists in the computer industry to reduce size,
weight and thickness of electronic devices. Typically, any computer
part that can be made smaller is made smaller to accommodate this
trend. By way of example, the wall thickness of the computer
housing has been made thinner over the years. In most instances,
decreased wall thickness reduces the overall thickness and weight
of the computer, both of which are desired to make a portable
computer more portable.
[0008] Nevertheless, making the outer structure thinner to reduce
computer weight and thickness has its drawbacks. As a general rule,
thicker walls mean stronger walls. Thus, as the walls are thinned,
the enclosure becomes more flexible. Consequently, the thinner
outer structure can not offer enough support to protect the
internal components of the computer. Even when the thinner outer
structure is strong enough to protect the internal components,
users who have come to expect rigid structures can be
unsatisfied.
[0009] Moreover, recently, computer housing designs have been
implemented in more complex shapes. These complex designs can
create structural problems that result in even more flexible outer
shells. The complex shapes can be contoured or curvilinear, which
generally reduces the overall strength of the computer housing. The
complex shapes also make it increasingly difficult to provide any
internal support to offset these problems.
[0010] One embodiment of the invention may be directed to reducing
the thickness in the housing in a region surrounding an opening
through which a display screen may be viewed. Normally, this
display screen is protected by a transparent wall. The transparent
wall typically is adhered to the interior surface of the housing
around the opening. In one embodiment of the invention, the housing
around the opening is reduced in thickness so a flange of the wall
can be placed in the housing. In this embodiment the transparent
wall may be flush with the interior surface of the housing. In one
embodiment of the invention, the transparent wall may be flush with
the exterior surface of the housing as well.
[0011] One purpose of the machined window undercut feature
according to the invention is to maximize the space available for
the electronics in the z-axis without sacrificing the strength of
the housing. In fact the machined window undercut may, in certain
embodiments, enhance the strength of the design.
[0012] Furthermore, the undercut feature can allow for a higher
capacity (thicker) battery and taller components on the main logic
board. The extra space can also make assembly of the electronics
into the housing simpler and more efficient. Such space is
especially important in selected models of the iPod.TM. device
manufactured by Apple Computer, Inc. of Cupertino, Calif. This is
because all the components can be installed through the top (or
bottom) of the product in this closed-back device and more space in
along the z-axis--i.e., the axis that runs vertically, toward the
viewer, when the viewer looks into the screen of the device--maybe
necessary.
[0013] The undercut window feature according to the invention can
be created by machining a recess in the area where the window will
mate with the inside of the housing. Because this product has a
closed-back cosmetic housing, a special cutter may be needed to
create this recess feature.
[0014] In one embodiment of the invention, the housing for the
device is extruded aluminum. The recess for the window can be cut
just deep enough to allow the housing to maintain its minimum wall
thickness--i.e., the wall thickness necessary to maintain the
structural integrity of the device and to sufficiently protect the
internal components--in that area. The window can then be adhered
to the housing in this recess, thereby saving space along the
z-axis.
[0015] Furthermore, one embodiment of the present invention can
facilitate manufacturing electronic devices having certain housing
designs such as closed backs. While conventional close-back device
may present manufacturing issues, the housing of the electronic
device may help to alleviate these issues, as described above, by
allowing more space in the z-axis.
[0016] A media player comprising a display screen is also provided.
The media player can include a housing having an opening and an
area of reduced thickness around the opening. The media player can
also include a transparent wall having a flange. Alternatively, the
transparent wall may not require a flange but rather can be a flat,
substantially transparent piece of material. The flange can be
adhered to a surface of the area of reduced thickness in order to
form a transparent protective cover for the display screen. In
another embodiment of the invention, a method is provided. The
method can include forming a transparent wall having a stepped edge
for placing in an opening of a media player. The method can also
include adhering an adhesive to at least one surface of the stepped
edge of the transparent wall and using the cutting tool to cut away
a portion of the underside of a housing that surrounds an opening
in a media player. The method can also include adhering the
transparent wall to the housing using the adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention is illustrated by way of example, and
not by way of limitation, in the figures of the accompanying
drawings and in which like reference numerals refer to similar
elements and in which:
[0018] FIG. 1 is a perspective view of a media player that may be
designed in accordance with one embodiment of the present
invention;
[0019] FIG. 2 is a top plan view of the screen portion of a media
player in accordance with one embodiment of the invention;
[0020] FIG. 3 is cross-sectional taken from line A-A of FIG. 1 in
accordance with one embodiment of the invention;
[0021] FIG. 4 is an exploded portion taken from line B-B of the
cross-sectional shown in FIG. 3 in accordance with one embodiment
of the invention;
[0022] FIG. 5 is a perspective view of a media player window and
portion of a media player in accordance with one embodiment of the
invention;
[0023] FIG. 6 is a top plan view of a media player housing and
special cutter in accordance with one embodiment of the
invention;
[0024] FIG. 7 is a side plan view taken from line C-C of a media
player housing and special cutter in accordance with one embodiment
of the invention;
[0025] FIG. 8 is another perspective view of a media player window
and portion of a media player in accordance with one embodiment of
the invention;
[0026] FIG. 9 an exploded portion similar to the exploded portion
shown in FIG. 4 in accordance with one embodiment of the
invention;
[0027] FIG. 10 is a flowchart describing a method in accordance
with one embodiment of the invention;
[0028] FIG. 11 is a flowchart describing another method in
accordance with one embodiment of the invention;
[0029] FIG. 12 is a top plan view of the screen portion of a media
player in accordance with another embodiment of the invention;
[0030] FIG. 13 is a cross-sectional view taken from line D-D of the
screen portion in FIG. 12 in accordance with one embodiment of the
invention; and
[0031] FIG. 14 is a perspective view of a media player window and
portion of a media player in accordance with one embodiment of the
invention.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0032] The present invention will now be described in detail with
reference to a few preferred embodiments thereof as illustrated in
the accompanying drawings. In the following description, numerous
specific details are set forth in order to provide a thorough
understanding of the present invention. It will be apparent,
however, to one skilled in the art that the present invention can
be practiced without some or all of these specific details. In
other instances, well known process steps have not been described
in detail in order not to unnecessarily obscure the description of
the present invention.
[0033] FIG. 1 is a perspective diagram of a media player 100, in
accordance with one embodiment of the present invention. The term
"media player" generally refers to computing devices that are
dedicated to processing media such as audio, video or other images,
as for example, music players, game players, video players, video
recorders, cameras, and the like. In some cases, the media players
contain single functionality (e.g., a media player dedicated to
playing music) and in other cases the media players contain
multiple functionality (e.g., a media player that plays music,
displays video, stores pictures and the like). In either case,
these devices are generally portable so as to allow a user to
listen to music, play games or video, record video or take pictures
wherever the user travels.
[0034] In one embodiment, the media player can be a handheld device
that is sized for placement into a pocket of the user. By being
pocket sized, the user does not have to directly carry the device
and therefore the device can be taken almost anywhere the user
travels (e.g., the user is not limited by carrying a large, bulky
and often heavy device, as in a laptop or notebook computer). For
example, in the case of a music player, a user can use the device
while working out at the gym. In case of a camera, a user can use
the device while mountain climbing. In the case of a game player,
the user can use the device while traveling in a car. Furthermore,
the device can be operated by the users' hands; no reference
surface such as a desktop is needed. In the illustrated embodiment,
the media player 100 is a pocket sized hand held MP3 music player
that allows a user to store a large collection of music. Although
used primarily for storing and playing music, the MP3 music player
shown herein can also include additional functionality such as
storing a calendar and phone lists, storing and playing games,
storing photos and the like. In fact, in some cases, it can act as
a highly transportable storage device.
[0035] Electronic device 10 can also be any miniature consumer
electronic device. Miniature electronic devices may have a form
factor that is smaller than that of hand-held devices. Illustrative
miniature electronic devices can include, but are not limited to,
watches, rings, necklaces, belts, accessories for belts, headsets,
accessories for shoes, virtual reality devices, other wearable
electronics, accessories for sporting equipment, accessories for
fitness equipment, or combinations thereof.
[0036] By way of example, the MP3 music player can correspond to
the iPod.TM. MP3 player manufactured by Apple Computer of
Cupertino, Calif. One pocket-sized IPod.TM. has a width of about
2.4 inches, a height of about 4 inches and depths ranging from
about 0.72 to about 0.84 inches.
[0037] As shown in FIG. 1, media player 100 FIG. 1 also shows
housing 102, display screen 104, scroll wheel 110, concave-faced
upper non-plastic portion of center button 112, that can be used
for user navigation through a user interface, holdswitch 114, and
earphone jack 116 of media player. Housing 102 can host center
button 112, and can in fact be configured to retain scroll wheel
110 in its position in the media player. Navigation can be
implemented in the form of transmission of user instructions in
response to user stimulus on scroll wheel 110.
[0038] In addition, housing 102 can also define the shape or form
of the media player. That is, the contour of housing 102 can embody
the outward physical appearance of media player 100. The integrated
circuit chips and other circuitry contained within the housing can
include a microprocessor (e.g., CPU), memory (e.g., ROM, RAM), a
power supply (e.g., battery), a circuit board, a hard drive, other
memory (e.g., flash) and/or various input/output (I/O) support
circuitry. The electrical components can also include components
for inputting or outputting music or sound such as a microphone,
amplifier and a digital signal processor (DSP). The electrical
components can also include components for capturing images such as
image sensors (e.g., charge coupled device (CCD) or complimentary
oxide semiconductor (CMOS)) or optics (e.g., lenses, splitters,
filters). The electrical components can also include components for
sending and receiving media (e.g., antenna, receiver, transmitter,
transceiver, etc.).
[0039] In the illustrated embodiment shown in FIG. 1, the media
player 100 includes display screen 104 and related circuitry.
Display screen 104 is used to display a graphical user interface as
well as other information to the user (e.g., text, objects,
graphics). By way of example, display screen 104 can be a liquid
crystal display (LCD). As shown, display screen 104 is visible to a
user of media player 100 through an opening 105 in housing 102, and
through transparent wall 106 (alternatively referred to herein as
"a window") that is disposed in front of opening 105. Although
generally transparent, transparent wall 106 can form part of the
housing 102 because it helps to define the shape or form of media
player 100 and, in some embodiments of the invention, can form a
substantially contiguous surface of the media player together with
housing 102.
[0040] As mentioned above, media player 100 also includes scroll
wheel 110. Scroll wheel 110 generally consists of touchable outer
surface 111 for receiving a finger for manipulation on scroll wheel
110.
[0041] The position of display screen 104 and scroll wheel 110
relative to housing 102 can be widely varied. For example, they can
be placed at any external surface (e.g., top, side, front, or back)
of housing 102 that is accessible to a user during manipulation of
media player 100. In the illustrated embodiment, scroll wheel 110
is located in a lower, front area of housing 102. Furthermore,
transparent wall 106 can be recessed below, level with, or extend
above the surface of housing 102. In the illustrated embodiment,
transparent wall 106 is substantially flush with the external
surface of housing 102.
[0042] The shape of display screen 104 and transparent wall 106 can
also be widely varied. For example, they can be circular,
rectangular, triangular, and the like. In general, the outer
perimeter of the shaped scroll wheel defines the working boundary
of the scroll wheel. In the illustrated embodiment shown in FIG. 1,
display screen 104 is rectangular and scroll wheel 110 is
circular.
[0043] In addition, media player 100 can also include one or more
buttons 112 configured to provide one or more dedicated control
functions, such as for making selections or issuing commands
associated with operating media player 100. Media player 100 can
also include hold switch 114. Media player can also include
headphone jack 116 and a data port (not shown).
[0044] FIG. 2 shows a top plan view of display screen 204 of media
player 100 (shown in FIG. 1) in accordance with one embodiment of
the invention. FIG. 2 shows screen 204 following assembly of the
media player. The following figures showing internal views of the
media player either during assembly of the media player according
to the invention or following assembly of the media player
according to the invention. FIG. 2 also shows opening 205 as well
as transparent wall 206.
[0045] As noted above with respect to FIG. 1, display screen 204 is
visible to a user of media player 100 through opening 205 in
housing 102, and through transparent wall 206 that is disposed in
front of opening 205. Although transparent, transparent wall 206
can be considered part of housing 102 because it helps to define
the shape or form of media player 100. In fact, as described above,
display screen 204, can be implemented flush with housing 102 which
may provide advantages such to prevent the collection of dirt
and/or dust in media player 100 and to prevent media player 100
from catching on to other surfaces.
[0046] FIG. 3 shows a cross-sectional taken from line A-A of FIG. 2
in accordance with one embodiment of the invention. FIG. 3 shows
undercut areas 302 and 304 in housing 305.
[0047] FIG. 3 also shows transparent wall 306. FIG. 3 also shows
flange 308 of transparent wall 306. In an embodiment of the
invention, undercut areas 302 and 304 are adapted to allow flange
308 to rest against undercut areas and to be adhered thereto. In
conventional media players, transparent wall would rest on the
housing without the undercut areas. This arrangement would take all
the space of the thickness of the window away from the inner space
in the housing. Thus, the space available for inner electronic
components and other components along the z-axis of the media
player was reduced. However, in a structure according to the
invention as shown in FIG. 4, available volume along the z-axis is
increased.
[0048] It should be noted that if transparent wall 306 is
implemented without a flange--i.e., as a flat piece of transparent
material--then surface of media player will no longer be flush in
the embodiment shown in FIG. 3 but rather can dip in at transparent
wall until the point at which the cutout portion allows transparent
wall 306 to abut.
[0049] FIG. 4 shows an exploded portion taken from line B-B of the
cross-sectional shown in FIG. 3 in accordance with one embodiment
of the invention. FIG. 4 shows transparent wall 402. Wall 402 can
incorporate a step so as to mate with undercut 406. FIG. 4 also
shows adhesive 404 for adhering wall 402 to housing 408.
[0050] Undercut 406 allows wall 402 to sit higher in housing 408.
This relationship makes more room for internal components.
[0051] This relationship also improves ease of assembly in
closed-back devices such as iPod.TM. media players. This
relationship improves ease of assembly because closed-back devices
can typically only be assembled from the top, the bottom or the
opening in the face of the housing. As described above, the
closed-back of a device typically limits the access to the internal
components once they have been inserted in the device. This can
make assembly of the device more challenging.
[0052] FIG. 5 shows a perspective view of a media player window and
portion of a media player according to the invention. FIG. 5 shows
housing 502, transparent wall 504 and adhesive 506. Alternative
configurations of adhesive 506 are described in more detail in FIG.
8 below.
[0053] FIG. 6 illustrates a top plan view of a media player housing
and special cutter according to the invention. FIG. 6 shows opening
605 in housing 602, customize cutter 606 for cutting undercut 607
into the underside of housing 602. Undercut 607 is shown in dotted
line because it is not visible from a top plan view of the outside
of housing 602.
[0054] It should be noted that the dimension in the x and y axes of
undercut 607 can be determined by the radius of cutter 606. This is
because, in one embodiment of a method according to the invention,
cutter 606 can be lowered through opening 605 and then used to cut
undercut 607 into the underside of the top surface of housing 602.
Furthermore, the sharpness of the corners of undercut 607 will also
be determined by the radius of cutter 606. Thus a mathematical
relationship is obtained between the radius of the corners of
undercut 607 and the radius of cutter 606.
[0055] The mathematical relationship may include the width of the
undercut required to present a sufficient surface onto which the
transparent wall flange can be adhered, the radius of the cutting
head in order to allow the cutting ahead to reach the required
width in the undercut while the shaft of the cutting tool does not
interfere with the ledge of the opening, and the radius of the
shaft.
[0056] FIG. 7 shows a side plan view taken from line C-C of FIG. 6
of a media player housing 702 and customized cutter 706 according
to the invention. Cutter 706 comprises cutter shaft 709 and cutter
head 708. FIG. 7 also shows cut out portion 710 of an undercut
according to the invention. Thus, FIG. 7 shows one side of an
undercut according to the invention.
[0057] FIG. 8 shows an exploded portion similar to FIG. 5. All the
elements of FIG. 8 are the same as in FIG. 5 with the single
difference being the shape and orientation of adhesive 804. In FIG.
8, adhesive 804 fills the additional cavities between wall 802 and
the undercut (not shown in FIG. 8) in housing 808 as well as at
least partially the vertical gap between housing 808 and wall 802.
This additional adhesive can provide additional structural
reinforcement and enhance the strength of the bond between wall 802
and housing 808.
[0058] FIG. 9 shows an exploded portion similar to FIG. 4. All the
elements of FIG. 9 are the same as in FIG. 4 with the single
difference being the shape and orientation of adhesive 904. In FIG.
9, adhesive 902 fills the additional cavities between wall 902 and
undercut 908 as well as the additional vertical wall between
housing 908 and wall 902. As described above, this additional
adhesive can provide additional structural reinforcement and
enhance the strength of the bond between wall 902 and housing
908.
[0059] In some embodiments of the invention, adhesive 904 can be
disposed both above undercut 906 and below undercut 906, as shown
in FIG. 9. Alternatively, adhesive 904 may be disposed in either
one direction--i.e., above or below undercut 906 but not both above
and below undercut 906. Of course, the specific application of
adhesive may be dictated based on manufacturing requirements. Other
additional applications of adhesives may include applying adhesives
as round dots or by other suitable application technique.
[0060] FIG. 10 shows a method according to the invention. Step 1010
shows forming a housing for storing components of a media player.
Step 1020 shows forming an opening in one of the faces of the
housing or, alternatively, molding a media player having an opening
from a suitable material such as carbon fiber. Step 1030 shows the
optional step of maintaining the face that opposes the face in
which the opening was formed as a closed face. Step 1040 shows
providing a cutting tool through the opening that was formed in
step 1020. Step 1050 shows using the cutting tool to cut away a
portion of the underside of the housing that surrounds the opening.
It should be noted that if the media player was molded, the
undercut could be provided as part of the molding process.
[0061] FIG. 11 shows another portion of a method according to the
invention. Step 1110 shows forming a transparent wall having a
stepped edge for placing in an opening of a media player. FIG. 1120
shows adhering an adhesive to either at least one surface of the
stepped edge of the transparent wall or to a cutout portion of the
housing of the media player. This step is drawn in dotted line to
emphasize that the adhesive could be applied to either the wall or
the housing.
[0062] Step 1130 shows placing the transparent wall through one end
in the housing. Step 1140 shows adhering the transparent wall to
one the housing using the adhesive.
[0063] FIG. 12 shows an alternative embodiment of the invention.
FIG. 12 shows display screen 1204 as it can be seen through
transparent wall 1206. Furthermore, opening 1205 is where screen
1204 can be viewed. However, in the embodiment shown in FIG. 12,
overcut 1207 is implemented on the top side of housing 1202 instead
of the underside.
[0064] With respect to the embodiment shown in FIG. 12, the corners
of overcut 1207 can be made to have a substantially smaller radius
than the corners of undercut 607 shown in FIG. 6. This can be due
to the fact that a cutting tool used to implement overcut 1207 does
not require a large radius because it does not have to cut deep
within the opening while preserving the edge of the opening as does
cutter 606 shown in FIG. 6. Rather, a cutter having a substantially
smaller radius can be used because the cutter can be directed to
exactly the portion being cut instead of having to reach under the
ledge of the opening, as shown and described in more detail in FIG.
6. Thus, a cutter used to implement overcut 1207 can include a
radius, or even a diameter, that is smaller than the width of
overcut 1207, while cutter 606 may comprise a radius that may be
even double the size or more than the width of undercut 607.
[0065] It should also be noted that if transparent wall 1206 is
implemented without a flange (not shown)--i.e., as a flat piece of
transparent material--then surface of media player can present a
surface that is flush with housing 1202. Nevertheless, the
thickness of wall 1206 will be less and, as such, may not provide
the level of protection to a display screen that a thicker
transparent wall, implementable by using a flanged, or stepped,
transparent wall, may provide.
[0066] FIG. 13 also shows the embodiment shown in FIG. 12. FIG. 13
shows this embodiment from line D-D of FIG. 12. FIG. 13 shows wall
1306 and overcut 1307. In FIG. 13, wall 1306 may be adhered to the
housing without having to put wall 1306 into housing. Rather, wall
1306 can be adhered directly onto overcut 1307 with an adhesive
similar to any of the embodiments described above with respect to
the adhesive being adhered to the undercut as shown, for example,
in FIG. 5 and/or FIG. 8.
[0067] The methods according to the invention can preferably
implemented by a combination of hardware and software, but can also
be implemented in hardware or software. The method can also be
embodied as computer readable code on a computer readable medium.
The computer readable medium is any data storage device that can
store data which can thereafter be read by a computer system.
Examples of the computer readable medium include read-only memory,
random-access memory, hard drive, flash memory, CD-ROMs, DVDs,
magnetic tape, optical data storage devices, and carrier waves.
[0068] In yet another aspect of the invention, the undercut portion
of the housing or the overcut portion of the housing may be
implemented wherever another element such as the audio jack 116,
the holdswitch 114 (as shown, for example, in FIG. 1) or any other
suitable element of the media player is mounted on the housing of
the media player. In each of these implementations, methods or
structures according to the invention may be used to reduce the
internal volume within the media player required to mount the
element.
[0069] In an additional embodiment of the invention, as shown in
FIG. 14, portion 1402, or portions 1402, of the cutout can be left
at the original thickness. In order to mate transparent wall 1404
with housing 1406, transparent wall 1404 and adhesive 1405 may be
designed accordingly. As shown in FIG. 14, adhesive 1405 may be
applied in multiple strips or deposits. The number of strips or
deposits of adhesive can depend on the shape and arrangement of the
multiple cutouts in housing 1406.
[0070] It is therefore intended that the following appended claims
be interpreted as including all such alterations, permutations, and
equivalents as fall within the true spirit and scope of the present
invention. The embodiments described herein-above are further
intended to explain the best modes known of practicing the
invention and to enable others skilled in the art to utilize the
invention in such, or other embodiments and with the various
modifications required by the particular applications or uses of
the invention.
[0071] Accordingly, the description is not intended to limit the
invention to the form disclosed herein. Also, it is intended that
the appended claims be construed to include alternative
embodiments.
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