AU2020201211B2 - Portable computer unified top case - Google Patents

Abstract

of the Disclosure Disclosed herein is a notebook computer. The notebook computer comprises a base portion comprising a glass housing member defining, as a unitary structure: a top wall defining an opening; and at least one side wall 5 integrally formed with the top wall. The base portion further comprises a bottom housing member coupled to the glass housing member, the glass housing member and the bottom housing member at least partially defining an interior cavity of the base portion; and an input device 10 extending at least partially through the opening in the top wall. The notebook computer further comprises a lid portion pivotally coupled to the base portion; and a display coupled to the lid portion.

Description

PORTABLE COMPUTER UNIFIED TOP CASE

This application is related to International Application Number PCT/US2009/060395 (International Publication Number WO 2010/045161) filed on 12 October 2009, the contents of which are incorporated herein by reference in their entirety. This application claims priority to United States patent application No. 12/353,242, filed January 13, 2009 and United States provisional patent application No. 61/105,035, filed October 13, 2008, which are hereby incorporated by reference herein in their entireties.

Background The present disclosure relates generally to portable computing devices such as notebook computers. More particularly, the present disclosure relates to enclosures for portable computing devices and to methods for assembling portable computing devices. Designers of portable computers are faced with competing demands. For example, it is generally desirable to reduce the weight of a portable computer, so that a user is not burdened by an overly heavy device. At the same time, durability and aesthetics should not suffer. Often, weight can be saved, but only at the expense of reducing the size or strength of device components. Similarly, it may be possible to improve device appearance, but only at the expense of making a device more fragile and susceptible to damage. For example, it can be difficult to form robust computer enclosures while satisfying desired performance and appearance criteria. Conventional computer enclosures are formed by assembling multiple pieces to create a single enclosure.

However, enclosures formed from multiple pieces add size, weight, complexity, can be relatively expensive, and can require an excessive amount of time to assemble the portable computer and the portable computer's enclosure. In addition, computer enclosures formed from multiple pieces assembled together have a relatively high probability of failure because the entire enclosure may fail if any single piece fails (e.g., because there are multiple failure points). Moreover, conventional computer enclosures can be difficult to recycle and therefore can be burdensome on the environment. For example, some of the pieces used to form the enclosure are typically formed non-recyclable materials that have to be removed from the enclosure before recycling. In addition, if the pieces are formed from different materials, the pieces may need to be separate and sorted before recycling. Glues and/or welding materials used to hold the pieces of the computer enclosure together may also interfere with recycling the enclosure. It would therefore be desirable to be able to provide improved enclosures that are more cost effective, smaller, lighter, stronger and aesthetically more pleasing than current enclosure designs. In addition, there is a need for improvements in the manner in which structures are mounted within the enclosures. For example, there is a need for improvements that enable structures to be quickly and easily installed within the enclosure, and that help position and support the structures in the enclosure. Reference to any prior art in the specification is not an acknowledgement or suggestion that this prior art forms part of the common general knowledge in any jurisdiction or that this prior art could reasonably be expected to be combined with any other piece of prior art by a skilled person in the art. By way of clarification and for avoidance of doubt, as used herein and except where the context requires otherwise, the term "comprise" and variations of the term, such as "comprising", "comprises" and "comprised", are not intended to exclude further additions, components, integers or steps.

Summary In a first aspect of the present invention, there is provided a notebook computer comprising: a base portion comprising: a glass housing member defining, as a unitary structure: a top wall defining: a keyboard region having an opening; and a trackpad region; and at least one side wall integrally formed with the top wall. The base portion further comprises a bottom housing member coupled to the glass housing member, the glass housing member and the bottom housing member at least partially defining an interior cavity of the base portion; and an input device extending at least partially through the opening in the keyboard region of the top wall. The notebook computer further comprises a lid portion pivotally coupled to the base portion; and a display coupled to the lid portion. In a second aspect of the present invention, there is provided a housing for a notebook computer, the housing comprising: a base portion comprising: a glass top member defining: a top wall having a keyboard region and a trackpad region and defining: a top exterior surface of the base portion; and an interior surface opposite the top exterior surface. The glass top member further defines a side wall defining a side exterior surface of the base portion; and a reinforcing member extending from the interior surface, integrally formed with the glass top member, and positioned between the keyboard region of the top wall and the trackpad region of the top wall. The base portion further comprises a bottom member coupled with the glass top member, the bottom member and the glass top member at least partially defining an interior cavity. The housing further comprises a lid member pivotally coupled with the base portion. In a third aspect of the present invention, there is provided a portable computer comprising: a base portion comprising: a unified glass housing member defining: a top wall defining: a keyboard region; and a trackpad region; and an outer wall defining: a continuous side surface that extends along three sides of the unified glass housing member; and a connector opening extending through the outer wall. The base portion further comprises a bottom housing member coupled with the unified glass housing member; and an electrical connector within the portable computer and accessible through the connector opening. The portable computer further comprises a lid portion pivotally coupled with the base portion; and a display coupled with the lid portion. Also disclosed herein is a top case assembly for a portable computer is disclosed. The assembly may include an integral unified (e.g., homogenous) top case formed from a single part. The integral top case provides an enclosure, frame and cosmetic exterior of the portable computer. The integral top case also serves as the primary structure of the portable computer. The assembly may include a variety of subassemblies such as keyboards, touchpads, circuit boards, and drives that are carried by the underside of the integral top case. The integral top case may be formed from a metal part such as an aluminum slab or an aluminum core that has been machined to form walls, openings, attachment areas, and cosmetic areas of the top case.

Brief Description of the Drawings FIGS. 1A and 1B are perspective views of an illustrative portable computer that may have a unified top

4A case in accordance with an embodiment of the present invention.

FIG. 2 is an exploded perspective view of an

illustrative base of a portable computer that may have a

unified top case in accordance with an embodiment of the

present invention.

FIG. 3A is a top perspective view of an illustrative

top case in accordance with an embodiment of the present

invention.

FIG. 3B is a bottom view of an illustrative top case

in accordance with an embodiment of the present invention.

FIGS. 4A-4D are perspective views of an illustrative

top case showing integral features of the top case in

accordance with embodiments of the present invention.

FIGS. 5A-5K are various views showing an assembly of

an illustrative portable computer that may have a unified

top case in accordance with an embodiment of the present

invention.

FIG. 6 is a flow chart of illustrative steps involved

in forming and assembling a portable computer in

accordance with an embodiment of the present invention.

FIG. 7 is a flow chart of illustrative steps involved

in forming a top case in accordance with an embodiment of

the present invention.

FIG. 8 is a flow chart of illustrative steps involved

in forming a top case in accordance with an embodiment of

the present invention.

FIG. 9 is a flow chart of illustrative steps involved

in forming a top case and involved in forming and

assembling a portable computer from the top case in

accordance with an embodiment of the present invention.

FIG. 10 is a diagram of illustrative steps involved

in forming a top case in accordance with an embodiment of

the present invention.

FIG. 11 is a diagram of illustrative steps involved

in forming a top case in accordance with an embodiment of

the present invention.

Detailed Description

The present invention relates to portable computer

structures. Portable computer structures may be provided

that enhance the functionality of a portable computer

while retaining or even improving desired levels of

durability and aesthetics.

One aspect of the invention may relate to a portion

of portable electronic device that includes an enclosure

formed by two parts (e.g., top case and bottom case). In

one embodiment, a majority if not all of the internal

components such as electrical components of the portion of

the portable electronic device are assembled within the

top case (sometimes referred to as the upper portion of

the computer's base unit) while the bottom case only

serves as a cover that cooperates with the top case

assembly to fully enclose the internal components (e.g.,

they cooperate to form the enclosure of the portion of the

electronic device). The top case may carry the electrical

components. The electrical components may be layered.

The top case may include attachment features on its

underside for securing the electrical components.

Another aspect of the invention may relate to a

housing portion (e.g., top case) that unifies several

structural/ornamental features into a single integral

part. For example, the housing portion may serves as a

protective shell with an integral frame while providing

the cosmetic exterior. With this type of arrangement, the

housing portion (e.g., primary case 20) may serve as an

exoskeleton for a portable computer such as a laptop

computer that provides structural strength while providing the cosmetic exterior. These three features may work together in one single part. The housing portion may also provide integral mounting features for helping secure various subassemblies within/to the housing portion. The housing portion may also serve as a heat sink to the portable electronic device.

In one embodiment, the integral housing portion may

be formed from a single slab of material, and more

particularly a single slab of metal material and even more

particularly a single slab of aluminum material. This

may, for example, be accomplished with one or more

machining operations. A majority if not all of the

surfaces of the integral housing portion may be machined

or otherwise formed. As an example, slabs may, for

example, be formed via an extrusion or similar process.

Slabs may generally have a similar profile as the profile

of the integral housing portion (e.g., side view, top

view, front view).

If desired, the integral housing portion may be

formed from an aluminum core which may be referred to as a

near-net-shape aluminum core. This type of aluminum core

may be formed from a piece of aluminum that is similar in

shape to the final shape of the integral housing portion.

That is, an aluminum core may follow the contour or form

of the integral housing portion (e.g., the integral

housing portion and the aluminum cores may both have

structures such as walls that are generally the same in

shape in size). Relatively less material may need to be

removed from the aluminum core than an aluminum slab to

form the integral housing portion (e.g., an aluminum slab

may have a substantially rectangular shape while an

aluminum core may have a near-net shape similar to the

shape of the integral housing portion). Because of this,

forming the integral housing portion from an aluminum core may reduce the amount of material that is machined away

(i.e., cut away) and thereby reduce the amount of material

such as machine cuttings that would otherwise need to be

disposed of or recycled.

The terms core, slab, aluminum core, aluminum slab,

and billet may be used interchangeably herein. For

example, a piece of material referred to as a slab may

also be referred to as a core without altering the

attributes of the piece of material.

Aluminum cores that are similar in shape to the final

shape of the integral housing portion may be formed using

any suitable method. For example, an aluminum core may be

formed using processes such as a rough forging, a forging,

a casting, a stamping, an investment casting, an extruding

process, etc. This type of arrangement may help to reduce

waste during manufacturing.

When the integral housing portion (e.g., primary case

) is formed from an aluminum slab (e.g., a rectangular

piece of unfinished aluminum), the finished integral

housing portion may have a weight that is about 60% less

or 50% less than the weight of the raw aluminum slab (or

% less, 30% less, 20% less, etc.). When the integral

housing portion is formed from an aluminum core (e.g., a

casting) that already has the rough shape of the integral

housing portion, the integral housing portion may have a

weight that is 50% or 30% less than the weight of the

original aluminum core (or 20% less, 10% less, etc.).

These are merely illustrative examples. Any suitable

amount of material may be removed from the original metal

part when forming the unified top case if desired.

Embodiments of the invention are discussed below with

reference to FIGS. 1-9. However, those skilled in the art

will readily appreciate that the detailed description

given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments.

FIG. 1 is a diagram of a portable computer 10, in

accordance with one embodiment of the invention. Portable

computer 10 may, for example, correspond to a laptop or

notebook computer. As shown, portable computer 10 may

include a base or main unit 12 and a lid or cover 14. The

lid 14 may rotate relative to base 12 about rotational

axis 16. The lid may, for example, be pivotally

(rotatably) coupled to the base via a hinge or clutch

barrel 18. As such, the lid 14 may rotate into an open

position (as shown) or a closed position (not shown)

relative to the base 12. The hinge 18 may be configured

to hold the lid 14 in various positions relative to the

base 12.

The internal components of the base 12 and lid 14 may

be surrounded at a peripheral region by a housing 13 and

, respectively, that serves to support the internal

components of the respective devices in their assembled

position. That is, the housings 13 and 15 may enclose and

support internally various components (including for

example integrated circuit chips and other circuitry) to

provide computing operations for the portable computer 10.

The housings 13 and 15 may also help define the shape or

form of the portable computer 10. That is, the contour of

the housings 13 and 15 may embody the outward physical

appearance of the portable computer 10. As such, they may

include various ornamental features that improved the

aesthetical appearance of the portable computer in both

open and closed positions.

In some instances, the internal components of the

base 12 and lid 14 may generate unwanted electrical

emissions (EMI), and therefore, housings 13 and 15 may be

configured to contain electronic emissions therein. By way of example, the housing may be formed from a suitable shielding material, i.e., a conductive material and/or a non-conductive material coated with a conductive material.

In other instances, the internal components may generate

undesirable heat, and therefore, the housings may be

configured to disperse the heat (e.g., transfer heat away

from a heat producing element through portions of the

housing).

Housings 13 and 15, which may sometimes be referred

to as cases or casings, may be formed from one or more

individual structures. Referring to housing 13 for

example, housing 13 may include a primary case 20 and a

cover 25 that cooperate to form the housing 13. The

primary case 20 may provide the primary structure of the

portable computer. For example, it may support the lid 14

as well as carry a majority if not all of the internal

components of the base 12 as well as the covers 25. The

primary case 20 may serve as the enclosure, frame, and

cosmetic exterior (very rigid structure). The covers 25

help close off the space provided by the primary housing.

In some embodiments, some portion of the covers 25 may act

as a removable portion 25 such as a door for providing

access to internal space inside the housing 13 or a

removable component such as a battery. The removable

portion 25 may be opened/locked via a latch arrangement

27.

Housing 13 and its associated components may, in

general, be formed from any suitable materials such as

such as plastic, ceramics, metal, glass, etc. The

material selected generally depends on many factors

including but not limited to strength (tensile), density

(lightweight), strength to weight ratio, Young's modulus,

corrosion resistance, formability, finishing,

recyclability, tooling costs, design flexibility, manufacturing costs, manufacturing throughput, reproducibility, and/or the like. The material selected may also depend on electrical conductivity, thermal conductivity, combustibility, toxicity, and/or the like.

The material selected may also depend on aesthetics

including color, surface finish, weight, etc.

In accordance with one embodiment, the housing may be

formed from a metal material, and further a machinable and

recyclable metal material.

In one particular embodiment, the housing may be

formed from aluminum. Some of the reasons for using

aluminum over other materials is that it is light weight

and structurally stronger (e.g., it has very good

mechanical properties and strength to weight ratio). This

is especially important for portable devices. Other

reasons for using aluminum include: reduced tooling costs,

its easily formable and extruded in a wide variety of

shapes including hollow parts, easily machinable thus

making it easy to alter the part and produce tight

tolerances, provides a near net shape, offers superior

corrosion resistance, it has high scrap value and is

routinely reprocessed to generate new products, it can be

finished using a variety of methods including mechanical

and chemical prefinishes, anodic coatings, paints and

electroplated finishes.

In one particular embodiment, the primary case 20 may

be formed from a solid block or core of machined aluminum

or other suitable metal. An advantage of forming housing

12 at least partly from aluminum is that aluminum is

lightweight, machinable, durable and attractive in

appearance. Aluminum may be anodized to form an

insulating oxide coating.

Machining may be performed to achieve various effects

as for example (1) to shape the enclosure and/or (2) to obtain a high degree of dimensional accuracy and surface finish and/or (3) to create openings and/or (4) to create structural features and/or (5) to create attachment features and/or (6) to create desired internal areas, and/or the like. The machining process may include one or more rough machining steps that remove a majority of material and create a flat part and then one or more a fine machining steps to create the final shape. One or more computer numerical control (CNC) machine tools may be used to perform some or all of the machining operations.

The base 12 may be configured to carry and provide

access to a variety of components. As shown, the base 12

may be configured to carry a variety of input devices such

as a keyboard 21 and a track pad or touch pad 22. In one

embodiment, the keyboard 21 and track pad 22 may be

located in a top portion of the primary casing 20. The

track pad 22 may be situated in the front of the top

portion (or palm rest) of the primary casing 20, and the

keyboard 21 may be situated in a back of the top portion

of the primary casing 20.

The keyboard 21, which includes a plurality of keys,

allows a user of the portable computer 10 to enter

alphanumeric data. In one embodiment, the keyboard 21 may

be arranged as a webbed keyboard, which includes a

plurality of spatially separated keys. The webbed

keyboard structure that surrounds the keys may, for

example, be integrated into the primary case 20 of the

base 12. That is, the top surface of the primary case 20

may have key openings that form a webbed structure that

surrounds the keys of the keyboard (defines the area

between the key openings/keys). In one implementation,

the key openings may be formed via a machining operation

that cuts holes through a top surface of the primary

housing. Alternative cutting operations may also be used in place of or in combination with the machining operation.

The track pad 22 may allow a user to move an input

pointer on a graphical user interface in addition to

gesturing and allowing a user to make a selection on a

graphical user interface. In one embodiment, the track

pad 22 may provide a mechanical clicking action for

further inputting (e.g., button inputting). In this

manner, the track pad 22 can include a single unbroken

surface that provides larger real estate for tracking

finger movements. Furthermore, the touch pad 22 may be

configured to be multi-touch, sensing more than one finger

at a time. The track pad 22 may be accessible through an

opening in the top surface of the primary housing 20. In

one implementation, the key openings may be formed via a

machining operation that cuts holes through a top surface

of the primary housing. Alternative cutting operations

may also be used in place of or in combination with the

machining operation.

The base 12 may also be arranged to carry a disk

drive 24 for performing various functions related to the

portable computer 10. By way of example, the disk drive

24 may be an optical disc drive configured to work with

optical discs such as CD's (e.g., CD, CDR, CD-RW, Video

CD, etc.), DVD's (e.g., DVD, DVD-audio, DVD-video, DVD-15

RW, etc.), mini-discs, magneto-optical discs and the like.

The disk drive 24 may be a slot loaded drive. By slot

loaded, it is meant that the disk is inserted directly

into the drive rather than by an external retractable tray

that moves in and out of the drive. As such, the primary

case 20 of the base 12 may include a disk opening that

allows a disk to be placed in the disk drive 24housed

within the base. In one implementation, the disk opening

or slot may be formed via a machining operation that cuts through a side wall of the primary housing. Alternative cutting operations may also be used in place of or in combination with the machining operation.

The base 12 may also be configured to carry various

ports 26 to which cables / connectors can be connected

(e.g., universal serial bus ports, an Ethernet port, a

Firewire port, audio jacks, card slots, etc.). The

primary casing 20 may include various port openings that

allow external cables / connectors to mate with the ports

of the base. Buttons and other controls may also be

situated within the primary casing 20 of the base 12.

These may be situated within openings in the primary

housing 20. In one implementation, the openings for

ports, buttons and controls may be formed via a machining

operation that cuts holes through a wall of the primary

housing. Alternative cutting operations may also be used

in place of or in combination with the machining

operation.

The base 12 may also be configured to carry various

indicator lights 28 to display status information to a

user. The indicator lights 28 may include windows or

holes on micro or macro level through which light may be

emitted from one or more light sources (e.g., light

emitting diodes). Depending on the size, machining

operations or other cutting operations such as laser

cutting may be used to form the windows or holes. The

windows and holes may include a transparent material

therein.

The base 12 may also be configured to carry speakers

and microphone 30 for outputting and inputting sound

information to/from the user. The primary case 20 may

include various openings to allow sound to pass through

the walls of housing 13. With one illustrative

arrangement, speaker openings may be formed in the housing of base by creating an array of small openings

(perforations) in the surface of housing 12. Depending on

the size, machining operations or other cutting operations

such as laser cutting may be used to form the speaker

openings.

The base 12 may include a lip 29 for gripping the lid

14 when closed. In one implementation, the lip 29 may be

formed via a machining operation that removes material

from a front wall of the primary housing (at the edge

proximate the closed lid 14).

The base 12 may also include one or more feet 31 for

supporting the portable computer on a flat surface. The

feet 31 may, for example, be placed near the corners of

the bottom surface of the cover 25 and removable portion

26. The feet may, for example, be bumpers that are

attached to the bottom surfaces.

Although not shown, the base 12 may be configured to

carry additional components such as hard drive, battery,

main logic board (MLB), and the like. In one embodiment,

a majority if not all of these internal components are

carried by the primary housing 20 of the base 12. The

primary housing may, for example, include various internal

features for helping secure these internal components

thereto (e.g., slots, undercuts, tabs, bosses, etc.). In

one implementation, these features may be formed via a

machining operation that removes material inside surfaces

of the primary housing. Other removal operations may also

be used in place of or in combination with the machining

operation.

Furthermore, although not shown, the base may include

various frame components and/or internal walls to increase

its rigidity and strength. The frame components and/or

walls are often internal features disposed within the base

12, and more particularly the primary case 20. In one embodiment, the frame components may be integral frame component (e.g., the frame components may be integrated with the primary case into a single unified piece). In one implementation, these features may be formed via a machining operation that removes material inside surfaces of the primary housing. Other removal operations may also be used in place of or in combination with the machining operation.

Although the lid 14 may include some of the

aforementioned components, the lid 14 may be configured to

carry a display 32 for presenting graphical information to

a user. The display 32 may be covered by or mounted

within the housing 15 of the lid 14. In one

implementation, the display 32 includes a hinge portion

that interfaces with a hinge portion of the primary

housing of the base 12 to allow the lid to rotate relative

to the base. In this manner, the housing 15 is carried by

the display 32. Alternatively, the housing may include a

hinge portion. As shown, the display 32 may be visible to

a user of the portable computer 10 when the lid 14 is in

the open position and no longer visible to the user when

the lid 14 is in a closed position. Display 32 may be,

for example, a liquid crystal display (LCD), organic light

emitting diode (OLED) display, or plasma display (as

examples).

In some embodiments, a glass panel may be mounted in

front of display 32. The glass panel may help add

structural integrity to computer 10. For example, the

glass panel may make the lid 14 more rigid and may protect

display 32 from damage due to contact with keys or other

structures. In one embodiment, the glass panel may be

formed from recyclable glass. In one embodiment, the

glass panel may substantially fill the entire front

surface of the lid 14. That is, the glass panel may extend substantially from one edge to the opposite edge of the lid 14. In these embodiments, the housing 15 may include a minimal side edge that surrounds the glass panel

(e.g., different from an extended surface that consumes a

portion of the front of the lid). This allows the display

area to be maximized while providing an aesthetically

pleasing look to the lid 14 (e.g., a black edge).

In accordance with one embodiment, the primary case

serves as the primary structure of the entire portable

computer 10. That is, it supports the components of the

base 12 and the lid 14 in addition provides strength and

stability to the lid 14 as wells as to the components

carried by the primary case 20. Moreover, it provides an

aesthetically pleasing look (i.e., forms a portion of the

ornamental appearance of the computer 10).

In accordance with one embodiment, the primary case

may be formed as a single integral part. By integral,

it is meant that the primary case 20 is a single complete

unit. By being integrally formed, the primary case is

structurally stronger than conventional housings, which

include parts that are fastened together. Furthermore,

unlike conventional housing parts that have seams between

the parts, the primary case has a substantially seamless

appearance. Moreover, this type of configuration helps

prevent contamination and is more water resistant than

conventional housings. In addition, by forming the

primary case as a single integral part, the recyclability

of device 10 and, in particular, primary case 20 may be

improved relative to conventional housings. For example,

because primary case 20 is formed from a single homogenous

material such as aluminum without substantial use of

adhesives, welds, or other metals, the primary case can

easily be melted down as part of an aluminum recycling

process. In essence, the primary housing 20 may be considered a precision unibody enclosure formed from a single piece of solid recyclable material (e.g., aluminum). As a result, it reduces many extraneous parts and allows the raw materials to be reused in other products.

In one embodiment, the primary case 20 includes a

horizontal planar top wall (surface) with integral and

substantially vertical planar side walls (e.g., four

integral side walls that are oriented perpendicular to the

top housing wall as shown in FIGS. 1A and 1B). The top

wall and side walls cooperate to define a cavity or void

into which the various components of the base 12 may be

mounted during assembly. The five walls are integrally

formed as a single part. The top wall and side walls may

be formed by machining a core of material (e.g., a slab of

aluminum).

In one embodiment, the base does not include a

separate frame assembly. Rather, the primary case 20

includes one or more integral frame members (e.g., ribs)

that provide structural rigidity to the top case. That

is, the frame members are homogenous with the rest of the

primary case 20. This set up reduces the number of

assembly steps as well as makes recycling the primary case

much easier. As should be appreciated, frames in

conventional components are often formed from disparate

materials that are fastened or glued to the housing

thereby making recycling much harder.

In one embodiment, the base eliminates some or all of

separate attachment features used to secure the components

within the base. Instead, the primary case 20 includes

one or more integral attachment features. These may, for

example, include tabs, slots, bridges, snaps, hooks,

catches, flexures, ribs, standoffs, bosses, and the like.

It should be appreciated however that some separate bracketing may be required to capture components such as a hard drive (which typically requires shock mounting) and an optical disk drive (which may include felt or other material to help prevent dust from entering the optical disk drive).

In one embodiment, it may be relatively easier to

assemble of portable computer 20 than conventional

portable computers. For example, because primary case 20

is formed from a single machined block and includes many

of the attachment features used to secure components

within the primary case, portable computer 20 may be

assembled relatively quickly as components can be screwed

directly into primary case 20 without the need to install

separated attachment features (which typically require

additional installation time).

In one embodiment, every surface of the primary case

is machined from a core of metal material such as

aluminum. That is, every surface of the primary case 20

is machined (inside and out).

In one embodiment, the top case includes undercuts,

recesses, protrusions, channels, and openings formed by

machining operations. Undercuts may help form attachment

features such as slots or channels underneath bridges.

Recesses may help create component zones such as zones for

placing a hard drive or an optical drive. Protrusions may

help create ribs for support or attachment points for

various components such as keyboards and main logic

boards. Channels may provide passages for wires or flex

circuits. Openings may provide access to various

components such as keys, track pads, ports, slots,

indicators, and the like.

It should be appreciated that conventional housings

typically include stamped materials or that are glued or

otherwise fastened together or alternatively plastic injected materials. In either case, the housing are further limited by the need for separate attachment features that are glued or otherwise fastened to the housings. This creates additional steps and a need for increased tolerance gap which encourages thicker devices thereby making them aesthetically unpleasing.

The integral top case described herein provides a

more accurate structure, reduced tolerances, thinner,

lighter and stronger enclosure. It eliminates the need

for weld bonds, glue bonds which can be thicker, weaker

and aesthetically unpleasing compared to integrally formed

features (e.g., features that are homogenous with the top

case).

FIG. 2 is an exploded view of a base 50 of a portable

computer, in accordance with one embodiment of the present

invention. The base 50 may, for example, correspond to

the base shown in FIG. 1. As shown, the base 50 includes

a top case 52, bottom cover 54 and an access door 56 that

cooperate to enclose a plurality of internal components

58. The top case 52 serves as the primary structure of

the entire base and further entire portable computer. In

one embodiment, the top case 52 is a single unified (e.g.,

homogenous) part that supports the internal components in

their desired position within the base. That is, the

internal components are mounted to and within the

underside of the top case 52. Although not shown, the top

case 52 includes a void into which the internal components

are positioned. The void is defined by integral top wall

and integral side walls 62 (e.g., the four integral

vertical planar side walls shown in FIG. 2) that surround

the edge of the top wall 60.

As shown, the top wall 60 includes a first set of

openings 64 for receiving individually and spaced apart

keys 66 of a keyboard 68. The top wall 60 also includes a second opening 69 for receiving a touch pad assembly 70.

The touch pad assembly 70 may include a platform that fits

within the opening 69. The platform may be movable in

order to provide a clicking action. It may, for example,

be cantilevered relative to the top wall 60 at the

backside of the opening 69. The side walls 62 may include

an opening 74 which provides access to an optical drive

76. The side walls 62 may additionally include various

openings 78 for access to ports 80. Although not shown,

the underside may include recesses and attachment points

for all the aforementioned components as well as main

logic boards 82 and hard drive 84. The attachment points

may provide a means for attaching such as snaps, clips,

tabs, slots or alternatively they may provide threads for

receiving screws.

Once the components are attached to the underside of

the top case 52, the bottom cover 54 may be secured to the

top case 52 thereby partially closing / covering the

internal components carried by the top case 52. The side

walls 62 may include a recess or flange that receives a

mating edge of the bottom cover. Screws may be used. The

open area still provided at the bottom may provide a

docking area for a battery 86. The battery docking area

may be closed off / covered by securing the access door 56

to the top case 52. A latching mechanism may be used to

engage and disengage the access door from the top case.

The top case 52 also includes a cut out for a hinge

portion and a lip for managing the opening of the lid when

the top case is assembled in a portable computer such as

the one previously described.

In one embodiment, the entire top case 52 is formed

by machining a core of aluminum to the desired shape and

size. This includes the walls, openings and attachment

features. As a result, the top case is an integrally formed housing structure, i.e., one homogenous part. The core may, for example, be an extruded piece of aluminum with a near net shape that is similar to the desired size and shape of the top case. In this example, material may be removed from the core to produce a top surface and integrally formed side walls that define the void or cavity. The material may also be removed to create the various openings, slots, ribs, frames, holes and the like.

As a result, the top case may be formed as a single

integral and homogeneous piece.

FIGS. 3A and 3B are top and bottom views,

respectively, of a top case 100 of a base, in accordance

with one embodiment of the present invention. The top

case 100 may, for example, correspond to the top case

shown in FIG. 2. The top case 100 is configured to serve

as the outer enclosure, inner frame and cosmetic exterior

of the base. In one embodiment, the top case 100 may be

formed entirely from a single homogeneous piece of

material. More particularly, it may be formed from a core

of metal such as aluminum or similar material. In one

embodiment, the top case 100 is formed by machining a

single core of material.

As shown, the top case 100 includes a top wall 102

and side walls 104 extending from the edge of the top wall

102. Because they are formed from the same piece of

material the walls are integral with one another. The top

wall 102 and side walls 104 may define a cavity or void

106 for placement of components of the base. The top and

side walls may also serve as attachment areas where the

components are mounted.

As shown in FIG. 3B, the top case 100 has been

machined to form various zones including for example a

keyboard zone 108, track pad zone 109, hard drive zone

110, battery zone 112, connector/port zone 105, an optical

drive slot zone 107, and a hinge zone 111.

The keyboard zone 108 includes a plurality of

machined openings 114 into which independent keys of the

keyboard are placed. The area around the openings creates

a webbed structure 116. This area may include various

features for attaching the keyboard. It may include

standoff or bosses and may even include threads for

receiving screws. This area may also include standoffs

118 for receiving other components that are laid over the

keyboard during assembly. For example, the top wall may

include standoffs for a main logic board (MLB) and an

optical drive (ODD). All of these are integrally formed

from the base material.

The track pad zone 109 includes a machined opening

120 and machined ribs 121 that surround the opening 120.

The back side rib 122 may include a bridge 123 for

receiving a tab of the track pad assembly such that it

cantilevers within the opening 120. The rib 122 may

extend across the length of the top wall to provide

strength and rigidity. The opening 120 may also include a

flange 124 that extends into the opening 120. The flange

124 is configured to support a switch which is activated

when the track pad is pushed downward (e.g., clicking

action).

The hard drive zone 110 may include features such as

undercut slots or voids that receive tabs or

cutouts/protrusions on the hard drive.

The battery zone 112 may include several recesses 130

for placement of magnets that help to secure lid 14 (e.g.,

housing 15) to base 12 (e.g., housing 13) when lid 14 is

in a closed position relative to base 12.

The connector zone 105 may include several openings

in case 100 (e.g., housing 13) that allow external cables with connectors to couple to ports in case 100 with corresponding connectors. As an example, these may openings may include openings for Ethernet® connectors,

USB@ connectors, audio connectors, power connectors, and

any other suitable connectors.

The optical drive zone 107 may include a single

elongated opening in case 100 that allows optical media

discs (e.g., compact discs or other optical media discs)

to pass from outside case 100 to an optical drive inside

case 100. The optical drive zone 107 may also include

other openings such as a button opening. The button

opening may allow a user to eject an optical media disc

from computer 10.

The hinge zone 111 may include recessed in which

hinge components are mounted and may include holes in

which hinge components formed as part of lid 14 are

recessed when lid 14 is coupled to case 100 (e.g., housing

13).

Although not specifically pointed out, it should be

appreciated that many features can be produced including,

for example, recesses of varying levels and wall

thicknesses of various thickness. It should also be

appreciated that points of stress may be machined to

provide added strength so as to reduce flexibility and

bending. It should also be appreciated that areas can be

machined away to provide space for internal components

such as flex circuits, printed circuit boards and the

like.

Referring to FIGS. 3A and 3B, as mentioned, various

outer shapes may be produced to affect the ornamental

appearance of the device 10 when utilizing machining

operations. In the illustrated embodiment, the top

surface and side surfaces may be substantially flat.

Furthermore the top surface and side surfaces may be substantially perpendicular thereby generating a sharp edge. Furthermore, the bottom edge of the walls may include a taper that substantially matches the taper of the cover and door that are mounted to the bottom of the top case to create a final assembly.

FIGS. 4A-4D are various views of machined integral

features of a top case, in accordance with one embodiment

of the present invention. The top case may, for example,

correspond to the top case shown in FIGS. 3A and 3B.

As shown in FIG. 4A, the side wall of the top case

includes an undercut area 150 for placement of a component

such as a light indicator assembly. The flange portion

156 may include a recess 154 for receiving an edge of a

bottom case or access door and a sloped section for

aesthetics. The top case may also include a boss 160 for

receiving a mounting screw and ribs 162 for separating

internal components and/or increasing structure integrity.

As shown in FIG. 4B, the top case may include

openings 164 and 166. As an example, openings 164 may be

openings for keys and openings 166 may be openings for

connectors such as audio connectors, Ethernet® connectors,

USB@ connectors, security lock connectors, etc. The top

case may also include stand offs 168 that help to prevent

a bottom case or access door from impinging on the

internal space within housing 13. The top case may also

include under cuts 170 which can provide additional space

for specific components (e.g., hinge components). The top

case may include bosses 172 that provide attachment points

to the top case (e.g., points which internal components, a

bottom case, or an access door can be secured to the top

case by screws).

As shown in FIG. 4C, the top case may include ribs

174 and flanges 176. Ribs 174 may be used to enhance

structural integrity and/or to divide the internal space in the top case (e.g., to separate internal components as desired). The top case may also include standoffs 178 that help to prevent a bottom case or access door from impinging on the internal space within housing 13 and threads 180 which can receive mounting screws (e.g., which can receive screws that hold internal components, a bottom case, or an access to the top case).

As shown in FIG. 4D, the top case may include a

bridge 182, cut outs 184, and recesses 186. Bridge 182

may allow internal connections to pass beneath the bridge

182 in the space between bridge 182 and the top case. Cut

outs 184 may be used to provide space for internal

components and/or wiring. If desired, cut outs 184 may be

used as mounting structures (e.g., internal components may

have mounting structures that fit into cut outs 184 and

align the internal components with the top case). Recess

186 may, as an example, hold magnets that are used to hold

a battery in the top case.

FIGS. 5A-5K are various views of a portable computer,

in accordance with one embodiment of the present

invention. The portable computer may, for example,

correspond and/or include any of the previous embodiments

including, for example, the top case.

FIGS. 5A-5E show a sequence of images showing

assembly of the portable computer, particularly various

components of the portable computer to a top case. FIG.

A shows providing a top case in step 200 (e.g., top case

of FIGS. 3-4). FIG. 5B shows attaching keyboard 204 (with

a fastener), track pad 206 (track pad 206 may include a

button such as a pickbutton and may be attached with a

fastener), speakers such as left speaker 208, right

speaker 210 and subwoofer 212, battery connector 214,

battery spring 216, a PC card cage such as PC card cage

and fingers 218, main I/O shields 220, slider mechanism

222, etc. to the top case in step 202. FIG. 5C shows

attaching a main logic board 226 (e.g., a MLB or

motherboard) (partially overlays keyboard 204) to the top

case in step 224. FIG. 5D shows attaching optical drive

230 (partially overlays keyboard 204) to the top case in

step 228. FIG. 5E shows attaching hard drive 234 to the

top case in step 232. These components may, for example,

be attached to portable computer (e.g., to the top case)

using fasteners such as screws. If desired, more

sensitive components may be mounted using shock mounts

(e.g., elastomeric and/or spring-based mounting

structures).

FIG. 5F shows attaching the lid 14 to the top case

assembly 100 (e.g., the top case assembly shown in FIGS.

A-5E). As shown, the lid 14 includes a hinge portion 18

that may be received by a cut out portion in the top case.

The hinge may be screwed to the top case assembly 100

(e.g., by 6 screws).

FIGS. 5G-5I show a sequence of images showing

assembly of the portable computer. FIG. 5G shows

attaching the bottom case 54 to the top case assembly 100

in step 236. FIG. 5H shows positioning the battery 86

within the battery dock area 112 of top case assembly 100

in step 238. FIG. 51 shows latching the access door 56 to

the top case 100 in step 240.

FIG. 5J shows 1) attaching the bottom case 54 to the

top case 100 and 2) inserting the battery 86 into the dock

area 112. The latching mechanism 27 is open and the

access door 56 is removed.

FIG. 5K shows 1) latching the access door 56 to the

top case 100 and 2) closing the latching mechanism 27.

FIG. 6 is a method 300 of assembling a portable

computer, in accordance with one embodiment of the present

invention. The portable computer may generally correspond to the portable computers and components shown in the previous figures. The method may, for example, correspond to the visual representation shown in FIGS. 5A-5K.

The method 300 may include block 302 where a base is

formed. This may include forming a top case, integrating

components into the top case and sealing the top case with

one or more covers.

The method 300 may also include block 304 where a lid

is formed. This may include forming a casing, and

integrating components into the casing (or vice versa).

For example, a casing may be attached to a display sub

assembly that includes a display and hinge mechanism for

attachment to the base.

The method 300 may also include block 306 where the

base and lid are assembled together. For example, the lid

and base are both mechanically and operatively coupled to

one another. The base and lid may be coupled via a hinge

system disposed therebetween. The hinge system allows the

lid to move between an open and closed position relative

to the base. The hinge system may also provide a means

for operatively connecting the components of the lid to

the components of the base. For example, it may provide

an electrical connection between a display and a main

logic board.

FIG. 7 shows illustrative steps involved in a method

350 of forming a top case in accordance with one

embodiment of the present invention. The method may, for

example, be utilized in block 302 in FIG. 6. The method

350 may include block 352 where a metal slab (e.g., a

metal core or a near net shape metal core) is provided.

The metal slab may have outer dimensions that are near the

desired dimensions of the top case. It may be slightly

larger in X, Y and Z dimensions. In one embodiment, the

metal slab is formed by extruding a metal in a long continuous length of material and segmenting the continuous length of material into a plurality of metal slabs. This may, for example, be accomplished by cutting the extruded metal at various points along its length.

The metal slab may also include finishing operations to

produce a flat surface. The flat surface may, for

example, be the outer surface of the top wall of the top

case. The flat surface may be used as a reference surface

during subsequent operations. Other walls may also

include finished surfaces.

The method may also include block 354 where

machining operations are performed on the metal slab

(e.g., the metal core or the near net shape metal core).

The machining operations may be performed in a variety of

steps including one or more rough machining steps and one

or more fine machining steps. The rough machining steps

are configured to remove a majority of the material out of

the metal slab in order to produce a rough top case. By

way of example, the rough machining operation may include

coring the slab to produce a part with a top wall and side

walls that form a cavity or void. In essence, the rough

machining operation forms the general shape of the desired

top case. The detailed machining steps are configured to

provide the detail work that is responsible for the fit,

finish and final precision of the part. The detailed

machining steps may include forming openings in the walls

such as key openings, port openings, speaker openings,

slots, and track pad openings. The detailed machining

steps may also include forming the final shape and

dimensions of the part including for example wall

thickness, and contours. The detailed machining steps may

also include forming attachment areas for the various

components of the base. The attachment areas may include

recesses, slots, bridges, bosses, brackets, frame members and the like. Some of the attachment areas are extended lengths while others are discrete points.

The method 350 may also include block 356 where one

or more finishing operations are performed. The finishing

operations may include blasting. The finishing operations

may also include grinding and/or polishing. In the case

of aluminum, the finishing operations may include

anodizing. The finishing operations may also include

etching anodized areas so as to expose the metal

underneath. These exposed areas may be used for EMI

and/or grounding connection points. In one example, laser

etching is used.

Thereafter, one or more post operations 358 may be

performed including for example forming small perforations

in the walls of the top case. The perforations may be

used for speaker grills as well as indicator lights. The

perforations may be macro or micro perforations depending

on the needs of the portable computer. In addition,

attachment points may be provided including for example

threads for screws, etc.

FIG. 8 is a method 400 of forming a top case, in

accordance with one embodiment of the present invention.

The method includes block 402 where an aluminum slab

(e.g., an aluminum core or a near-net shape aluminum core)

or similar metal is formed by extrusion and segmenting the

extrusion.

The method 400 also includes block 404 where at least

one of the surfaces of the slab is flattened. The

flattened surface provides a reference surface for future

operations. The surfaces may, for example, be flattened

using a fly cut machining operation. The metal slab is

machined in order to provide flat surfaces.

The method 400 may also include block 406 where a

rough machining operation is formed on the slab in order to create a near net shape of a top case. The rough machining operation may include forming a cavity in the slab such that a top wall and side walls are formed. The rough machining operation may, for example, be performed using computer numerical control (CNC) techniques. In some embodiments, the rough machining operation may be performed in one step. The rough shape of the casing is formed.

The method 400 may also include block 408 where one

or more detail machining operations are performed. The

detail machining operations may include machining the part

to its desired shape and surface finish as well as

machining in openings, frame members, channels and

attachment areas/structures into the various walls

including top wall and side walls that define the void.

The detailed operations may be performed in a variety of

CNC operations. Some operations may be dedicated to

forming undercuts while others are dedicated to forming

openings and/or recessed. In some embodiments between 5

12 detail machining operations are performed. These often

occur in different CNC machines. During these operations,

the fine shape of the casing is formed

The method 400 also includes block 410 where the

surfaces of the top case are blasted and thereafter in

block 412 the aluminum top case is anodized. The method

may additionally include block 414 where small

perforations are formed through the walls of the top case.

The small perforations may be associated with speakers,

microphones, as well as indicator lights.

FIG. 9 is a method 500 of manufacturing a portable

computer in accordance with a detailed embodiment of the

present invention.

Method 500 may include block 502 where an aluminum

slab (e.g., an aluminum core) is extruded and segmented.

Extrusion is a process where material is pushed or drawn

through a die to create the desired cross sectional shape.

The process typically generates a continuous long length

of product. Once extruded, the metal slab is typically

separated from the continuous length of product (e.g., the

metal slab is a segment of the extruded length).

Method 500 may include block 504 where a top surface

of the slab is flycut in order to produce a flat surface.

Method 500 may include block 506 where the underside

of the slab is machined to form a void which will receive

the components therein. The void is typically defined by

the top wall and side walls that surround the edge of the

top wall. Although referred to as separate elements, it

should be appreciated that the top wall and side walls are

integral as they are formed from the same part. This

makes the part more structurally sound. It also

eliminates steps such as fastening. Conventionally, these

elements are glued or otherwise fastened together (not an

integral part). The slab may, for example, be machined

using a rough CNC operation.

Method 500 also includes block 508 where the

remaining surfaces of the part are machined. This block

includes forming internal features within the void. These

internal features include forming channels for placement

of wires and cables, snaps/clips for securing components,

slots for receiving tabs of components. Block 508 may be

performed in a series of detailed CNC machining

operations.

Method 500 may also include block 510 where the part

is blasted. The blasting operation may be performed to

create a rough (matte) but uniform finish. By way of

example, the blasting operation may use silicone carbide

or other suitable materials as a medium.

Method 500 may also include block 512 where the part

is anodized.

Method 500 may also include block 514 where select

areas of the anodized surface are laser etched in order to

form exposed aluminum areas.

Method 500 may also include block 516 where a series

of perforations are formed in the top wall in order to

form an integrated speaker grill. This may, for example,

be accomplished using laser drilling.

The method 500 may also include block 518 where

various microperforations are formed in the side walls of

the top case. The microperforations may be used for

indicator lights. Microperforations are not visible at

the surface until light is provided therethrough. If

desired, the perforations formed in steps 516 and 518 may

formed after anodizing the top case 20. By forming the

perforations of steps 516 and 518 after anodizing the top

case, the visual appearance of the perforations may be

improved. For example, the anodizing process may alter

the visual appearance of perforations that are formed

prior to the anodizing process by either altering the size

of the perforations (which could possibly completely close

the openings created by the perforations) or by giving the

perforations a sparkling appearance (which may or may not

be desirable).

The method 500 also includes block 520 where various

components are installed to the top case. This is

generally accomplished using a layered approach. That is,

the components may layer or stack on top of one another

within the void of the top case. By way of example, the

keyboard may be positioned relative to the key openings in

the top wall and the keyboard may be screwed into the top

wall using a plurality of screws. The screws may be

strategically placed about the keyboard. The screws may be threaded into the webbed structure that defines the openings around the keys in addition to the area around the webbed structure. Furthermore, the main logic board

(MLB), optical disk drive (ODD), hard disk drive (HDD) and

thermals in addition to other components may be secured.

The method 500 also includes block 522 where the lid

is assembled to the top case assembly. For example, it is

mechanically coupled via a hinged clutch mechanism and

operatively coupled through one or more flex circuits or

wires that pass through the clutch mechanism.

The method 500 also includes block 524 where

attaching a bottom cover to the top case over the void.

The cover may partially cover the void in order to form a

battery docking area.

The method 500 also includes block 526 where an

access cover (e.g., door) is secured over the battery

docking area such that the internal components are fully

enclosed within the top case, bottom cover and the access

cover.

Throughout the process, the method 500 may include

cleaning and inspection processes. The inspection may

include micro photography as well as dimensional analysis.

Testing may include testing the various components as they

are installed into the housing.

FIG. 10 is a simplified diagram of a method 606 used

to create a metal housing member 608, in accordance with

one embodiment of the present invention. The metal

housing member 608 may be used in an electronic product

such as a computer, and more particularly portable

electronic devices such as portable computers. The metal

housing member 608 may be configured to be the primary

structural and cosmetic part of the electronic device. In

fact, the metal housing member 608 may act as an

exoskeleton that provides a base for carrying/supporting most if not all of the electronics, circuitry and other operational components of the electronic device, an enclosure for surrounding/protecting these components, and an ornamental/cosmetic feature of the electronic device.

The metal housing member 608 may be a single unified

homogeneous part (e.g., a unified top case). That is, it

is not put together by fasteners, welds, glues and the

like. As a result, the metal housing member 608 may be

relatively easy to recycle (e.g., because there are not

addition fasteners, welds, glues, or non-homogenous

materials that need to be separated from member 608 before

recycling). In one particular embodiment, the metal

housing member is formed from aluminum or other similar

metal.

As shown, the method 606 starts with a base material

607 that is turned into a metal core 609 (e.g., a metal

slab, a metal core, an aluminum slab, an aluminum core, a

metal billet, an aluminum billet, etc.). In one example,

the core is formed via an extrusion process that produces

a uniform and continuous length of a desired shape, which

is cut to form a block having dimensions larger than the

outer dimensions of the metal housing member being cut

therefrom. In some cases, the dimensions are only

slightly larger. As shown by the dotted lines, the metal

housing member 608 is a 3D object disposed inside the

block. As shown by the dotted lines, the metal housing

member may include a top wall with integral side walls.

It should be appreciated that although not shown in FIG.

, the integral side walls may include four side walls

that extend from the top wall. The top wall and side

walls may, for example, define a cavity for placement of

the internal electronic components. In one embodiment,

the metal housing member is a primary structure of the

main enclosure of the electronic device. In the context of a portable computer, for example, the metal housing member may be a top case. The metal housing member may serve as a platform for attaching the internal electronic components. For example, the electronics may be attached to the inner surfaces of the top and side walls.

In order to obtain the object or the final shape, the

unwanted material is selectively removed away from the

block. In essence, the block is being carved away to

produce a sculpture in the form of a housing member. It

is a subtractive method rather than an additive method.

This may, for example, be accomplished with one or more

machining operations. Machining operations may be used to

form walls, create openings in the walls so that

electronic components can be accessed, create structural

features such as ribs that strengthen the housing member,

create internal attachment features for securing and

correctly placing electronic components, form a cosmetic

exterior, etc. The machining operations may include both

rough and fine machining operations. In one example, the

machining operations are performed via a CNC machine.

In one embodiment, a majority of the surfaces of the

metal housing member have been cut or carved. As such,

the desired shape and dimensional accuracy can be easily

achieved. In another implementation, all of the outer

surfaces of the metal housing member are cut or carved

away (e.g., machined). Additionally or alternatively, a

portion of the inner surfaces of the metal housing member

may be cut away. As should be appreciated, the innards

typically are not cosmetic and can thus be left alone

(e.g., not cut or carved away) if the original metal core

shape allows for this. More particularly, however, a

majority of the inner surfaces may be cut away and, even

more particularly, all of the inner surfaces may be cut away. In one particular embodiment, all of the surfaces are machined (as shown by the arrows in FIG. 10).

FIG. 11 is a simplified diagram of a method 611 used

to create a metal housing member 608, in accordance with

an embodiment of the present invention. FIG. 11 is

similar to FIG. 10 in that the metal housing member is

carved or sculpted from a metal block. However, instead

using a metal core 609 that is shaped like a block, method

611 may use a metal core 617 that generally follows the

shape of the final desired form of the metal housing 608.

For example, the metal core may be formed to have a

similar shape with slightly increased dimensions such that

the desired shape can be formed by removing a layer of

material from the surface of the metal core. By way of

example, the metal core may generally have a top surface,

and side walls that form a cavity therein. This metal

core may, for example, be formed via a casting, a rough

forging, a forging, a stamping, an investment casting, an

extrusion process, or any other suitable technique.

FIGS. 10 and 11 may, in general, correspond to any of

the methods and systems and components mentioned

previously in FIGS. 1-9.

In accordance with an embodiment, a portable computer

is provided that includes a lid and a base to which the

lid is rotatably connected, where the base includes a

unified top case formed from a single piece of metal and

all surfaces of the unified top case are machined.

In accordance with another embodiment, the portable

computer also includes a plurality of keys and the unified

top case includes a planar surface having portions that

define openings for the keys.

In accordance with another embodiment, the unified

top case includes integral planar sidewalls that are

perpendicular to the planar surface.

In accordance with another embodiment, the unified

top case includes four integral planar sidewalls that are

perpendicular to the planar surface.

In accordance with another embodiment, the lid

includes a display.

In accordance with another embodiment, the portable

computer also includes a plurality of subassemblies

attached to an inner surface of the unified top case.

In accordance with another embodiment, the metal

includes aluminum and the unified top case is formed

exclusively from the aluminum.

In accordance with another embodiment, the top case

includes an integral frame member and attachment features.

In accordance with an embodiment, a method of forming

an integral top case for a portable computer having

circuitry is provided that includes machining

substantially all surfaces of a metal part to produce a

single finished part that serves as the integral top case,

that encloses the circuitry in the portable computer, that

provides structural support for the portable computer, and

that provides a cosmetic exterior for the portable

computer.

In accordance with another embodiment, machining the

metal part includes machining an aluminum core using a

rough machining operation and at least one detailed

machining operations.

In accordance with another embodiment, the metal part

includes an aluminum slab, machining the metal part

includes producing a flat surface on the single finished

part, and the flat surface serves as at least part of the

cosmetic exterior for the portable computer.

In accordance with another embodiment, the metal part

includes a rough aluminum casting of the single finished

part, machining the metal part includes performing a flycut operation to produce a flat surface on the single finished part, and the flat surface serves as at least part of the cosmetic exterior for the portable computer.

In accordance with another embodiment, the single

finished part has a weight that is less than fifty percent

of the weight of the metal part before the machining of

the metal part and the method also includes performing an

anodizing operation to produce the single finished part.

In accordance with another embodiment, the single

finished part has a weight that is less than fifty percent

of the weight of the metal part before the machining of

the metal part and the method also includes anodizing the

single finished part.

In accordance with another embodiment, the method

also includes after machining the metal part to produce

the single finished part, anodizing the single finished

part.

In accordance with another embodiment, the method

also includes after anodizing the single finished part,

creating perforations in the single finished part.

In accordance with another embodiment, the single

finished part includes aluminum and the method also

includes after anodizing the single finished part, etching

anodized portions of the single finished part to expose

aluminum portions of the single part.

In accordance with an embodiment, a portable computer

that has a base and a lid is provided that includes a

display mounted in the lid, circuitry mounted in the base

of the portable computer, and an integral top case in the

base formed as a single part that serves as an exoskeleton

for the base, where substantially all surfaces of the

single part are machined surfaces that have been machined

with a machining tool.

In accordance with another embodiment, the integral

top case that serves as the exoskeleton for the base is

formed exclusively from metal and provides an enclosure

for the circuitry, serves as a primary structure for the

portable computer, serves as an exterior top surface, and

the portable computer also includes a hinge that connects

the lid to the single part.

In accordance with another embodiment, the portable

computer also includes a bottom case that connects to the

integral top case to substantially enclose the circuitry.

In accordance with another embodiment, the integral

top case includes attachment features used to secure the

circuitry within the base.

In accordance with another embodiment, the portable

computer also includes keyboard keys and the integral top

case is formed exclusively from metal and has portions

defining openings for the keys.

In accordance with another embodiment, the integral

top case has a substantially planar top surface, the

portions defining openings for the keys are part of the

substantially planar top surface, and the portable

computer also includes four integral planar sidewalls each

of which is an integral part of the integral top case and

each of which is perpendicular to the substantially planar

top surface.

In accordance with another embodiment, the integral

top case also includes portions defining speaker grill

perforations and portions defining internal attachment

features and the integral top case is formed from a single

piece of anodized aluminum.

In accordance with an embodiment, a method is

provided that includes obtaining a single core of metal

material, with at least one computer numerical control

machining tool, machining substantially all surfaces of the single core of metal material to form a single unified metal housing member with integral features, the integral features including a top wall and side walls extending from the top wall, the top wall and side walls defining a cavity, one or more surfaces of the cavity including one or more integral attachment points, and attaching electronic components within the cavity of the single unified housing member via the one or more integral attachment points, the single unified housing member being configured to act as an exoskeleton that surrounds, supports and carries the internally attached electronic components.

In accordance with another embodiment, the single

unified housing member supports a majority of the

electronic components of a portable computer.

In accordance with another embodiment, the single

unified housing member is the primary structure of an

enclosure, the single unified housing member supporting

substantially all of the electronic components of a

portable computer.

In accordance with an embodiment, a unibody top case

for a portable computer is provided that includes a single

homogeneous aluminum part that includes integral features,

where substantially all surfaces of the single aluminum

part are machined surfaces that have been machined using a

computer numerical control machining tool, the integral

features including a top wall and side walls that form an

exoskeleton of the portable computer, the exoskeleton

providing a cosmetic exterior, an outer protective shell,

and a primary structural support structure for the

portable computer, the exoskeleton supporting a plurality

of electronic components of the portable computer.

In accordance with another embodiment, the top wall

and side walls are formed of planar machined surfaces.

In accordance with another embodiment, the integral

features include attachment points for mounting the

electronic components to an inside surface of the unibody

top case.

In accordance with another embodiment, the side walls

extend downwardly from the top wall thereby forming a

cavity into which the electronic components are placed.

In accordance with another embodiment, an outer

surface of the top wall is flat and outer surfaces of the

sidewalls extend substantially perpendicularly from the

outer surface of the top wall.

The foregoing is merely illustrative of the

principles of this invention and various modifications can

be made by those skilled in the art without departing from

the scope and spirit of the invention.

Claims (20)

What is claimed is:

1. A notebook computer comprising: a base portion comprising: a glass housing member defining, as a unitary structure:

a top wall defining: a keyboard region having an opening; and a trackpad region; and at least one side wall integrally formed with the top wall; a bottom housing member coupled to the glass housing member, the glass housing member and the bottom housing member at least partially defining an interior cavity of the base portion; and an input device extending at least partially through the opening in the keyboard region of the top wall; a lid portion pivotally coupled to the base portion; and a display coupled to the lid portion.

2. The notebook computer of claim 1, wherein the glass housing member further comprises a rib member integrally formed with the top wall and positioned within the interior cavity between the keyboard region and the trackpad region.

3. The notebook computer of claim 2, wherein: the rib member is a first rib member; the at least one side wall is a front side wall of the glass housing member; the lid portion is pivotally coupled to the base portion along a back side of the glass housing member; and the glass housing member further defines a second rib member extending from the front side wall to the back side of the glass housing member.

4. The notebook computer of claim 2, wherein: the opening is a first opening; the top wall defines a second opening in the trackpad region; and the base portion further comprises a trackpad extending at least partially through the second opening.

5. The notebook computer of claim 4, wherein: the rib member is a first rib member; the first rib member is positioned along a first side of the second opening; and the glass housing member further comprises a second rib member integrally formed with the top wall and positioned along a second side of the second opening.

6. The notebook computer of claim 4, wherein: the top wall defines a key web that defines the first opening and a plurality of additional openings; the base portion further comprises a keyboard at least partially within the interior cavity; the keyboard comprises a plurality of keys; and a key of the plurality of keys extends at least partially through the first opening.

7. The notebook computer of claim 6, wherein the rib member is positioned between the key web and the second opening.

8. The notebook computer of claim 6, wherein: the rib member is a first rib member; the key of the plurality of keys is a first key; a second key of the plurality of keys extends at least partially through one additional opening of the plurality of additional openings; and the unitary top case further defines a second rib member positioned between the first opening and the one additional opening.

9. A housing for a notebook computer, the housing comprising: a base portion comprising: a glass top member defining: a top wall having a keyboard region and a trackpad region and defining: a top exterior surface of the base portion; and an interior surface opposite the top exterior surface; a side wall defining a side exterior surface of the base portion; and a reinforcing member extending from the interior surface, integrally formed with the glass top member, and positioned between the keyboard region of the top wall and the trackpad region of the top wall; and a bottom member coupled with the glass top member, the bottom member and the glass top member at least partially defining an interior cavity; and a lid member pivotally coupled with the base portion.

10. The housing of claim 9, wherein: the top wall further defines a key web in the keyboard region; the base portion further comprises a keyboard at least partially within the interior cavity; the keyboard comprises a plurality of keys; and a key of the plurality of keys extends at least partially through a key opening defined by the key web.

11. The housing of claim 9, wherein the side wall defines an undercut.

12. The housing of claim 9, wherein: the side wall defines a connector opening; and the connector opening is configured to receive a plug.

13. The housing of claim 9, wherein: the side wall is a first side wall; the glass top member further defines: a second side wall; and a third side wall; and the first side wall, the second side wall, and the third side wall form a continuous surface around at least a portion of a periphery of the housing.

14. The housing of claim 13, wherein: the first side wall defines a first undercut positioned along a first edge of the housing; the second side wall defines a second undercut positioned along a second edge of the housing; and the third side wall defines a third undercut positioned along a third edge of the housing.

15. The housing of claim 13, wherein: the first side wall defines a first connector opening configured to receive a first electronic connector; and the second side wall defines a second connector opening configured to receive a second electronic connector.

16. A portable computer comprising: a base portion comprising: a unified glass housing member defining: a top wall defining: a keyboard region; a trackpad region; and an outer wall defining: a continuous side surface that extends along three sides of the unified glass housing member; and a connector opening extending through the outer wall; a bottom housing member coupled with the unified glass housing member; and an electrical connector within the portable computer and accessible through the connector opening; a lid portion pivotally coupled with the base portion; and a display coupled with the lid portion.

17. The portable computer of claim 16, wherein: the top wall further defines a key web defining a key opening; the base portion further comprises a keyboard at least partially within the portable computer; the keyboard comprises a plurality of keys; and a key of the plurality of keys extends at least partially through the key opening.

18. The portable computer of claim 16, wherein one or more electrical connections pass through the connector opening.

19. The portable computer of claim 16, wherein: the top wall defines a notch along a back side of the top wall; the lid portion is pivotally coupled with the base portion via a hinge mechanism; and the hinge mechanism is positioned at least partially in the notch.

20. The portable computer of claim 16, wherein the connector opening defines an undercut in the continuous side surface.