Electronic device having a display and method for manufacture
A method of making a device housing involves providing a transparent lens with a front surface and a rear surface, and a stepped flange along at least a portion of the lens perimeter. The method includes injecting plastic onto the transparent lens perimeter, including the stepped flange, the plastic forming a plastic feature that has a front surface that is tangent to the front surface of the transparent lens, a rear surface that is tangent to the rear surface of the transparent lens, and that extends outward from the sides of the transparent lens away from a device width center line. The plastic feature is molded to the rear surface of the transparent lens at at least one of two ends of the device housing, and the plastic encapsulates a stepped middle surface of the transparent lens flange. A device housing that is made by this method is also included.
1. A method of making a device housing, the method comprising:
providing a transparent lens with a front surface and a rear surface, and a stepped flange along at least a portion of the lens perimeter;
applying an oleophobic coating to the front surface of the transparent lens;
injecting plastic onto the transparent lens perimeter, including the stepped flange, the plastic forming a plastic feature that has a front surface that is tangent to the front surface of the transparent lens, a rear surface that is tangent to the rear surface of the transparent lens, and that extends outward from the sides of the transparent lens away from a device width center line;
applying optically clear light curable resin on the rear surface of the transparent lens;
placing a display module on the resin; and
optically curing the resin with at least one optical source;
wherein:
a first boundary between the front surface of the transparent lens and the plastic feature is closer to a center line of the transparent lens than a second boundary between a back surface of the transparent lens and the plastic feature,
the plastic feature is molded to the rear surface of the transparent lens at at least one of two ends of the device housing; and
the plastic encapsulates a stepped middle surface of the transparent lens flange.
2. A method of making a device housing, the method comprising:
providing a transparent lens with a front surface and a rear surface, and a stepped flange along at least a portion of the lens perimeter;
injecting plastic onto the transparent lens perimeter, including the stepped flange, the plastic forming a plastic feature that has a front surface that is tangent to the front surface of the transparent lens, a rear surface that is tangent to the rear surface of the transparent lens, and that extends outward from the sides of the transparent lens away from a device width center line; and
applying an oleophobic coating to the front surface of the transparent lens,
wherein:
the plastic feature is molded to the rear surface of the transparent lens at at least one of two ends of the device housing; and
the plastic encapsulates a stepped middle surface of the transparent lens flange.
3. The method as defined in claim 1 , further comprising, prior to injecting the plastic, applying an adhesive to the flange edges of the transparent lens.
4. The method as defined in claim 3 , the oleophobic coating preventing the adhesive from sticking to the front surface of the transparent lens.
5. The method as defined in claim 1 , wherein a decorative ink on the transparent lens rear surface defines a viewing area of at least one edge of the display.
6. The method of claim 5 , further comprising:
applying optically clear light curable resin on the transparent lens rear surface;
placing a display module on the resin; and
optically curing all of the resin using only a front optical source and a rear optical source.
7. The method as defined in claim 1 , wherein a housing plastic to transparent lens material front surface transition line defines a viewing area of at least one edge of the display.
8. The method of claim 7 , wherein the front surface transition line is closer to a device width center line than a rear surface boundary of the plastic and transparent lens.
9. A method of making a device housing:
creating a transparent lens with a front surface and a rear surface, and a stepped flange along at least a portion of the lens perimeter;
applying an oleophobic coating to the front surface of the transparent lens;
applying an adhesive to the flange edges of the transparent lens;
injecting plastic onto the transparent lens perimeter, including the stepped flange, the plastic forming a plastic feature that has a front surface that is tangent to the front surface of the transparent lens, a rear surface that is tangent to the rear surface of the transparent lens, and that extends outward from the sides of the transparent lens away from a device width center line;
defining a housing plastic-transparent lens material rear surface transition line as a viewing area of at least one edge of the display;
applying optically clear light curable resin on the transparent lens rear surface on both sides of the transition line;
placing a display module on the resin; and
optically curing all of the resin using only a front optical source and a rear optical source;
wherein:
the plastic feature is molded to the rear surface of the transparent lens at at least one of two ends of the device housing; and
the plastic encapsulates a stepped middle surface of the transparent lens flange;
the front surface boundary is closer to a device width center line than a rear surface boundary of the plastic and transparent lens.