G2 3D Design Review

Agenda MIN CST Topic 10 09:30 AM - 09:40 AM | Product Intro (Features / Assy View / XYZ Stacks) 30 09:40 AM - 10:10 AM | Housings & Materials // Accessories 20 10:10 AM - 10:30 AM | Connectors & Contacts // PCBs & Flex Circuits 20 10:30 AM - 10:50 AM | Lenses and Glass // Touch Sensing 15 10:50 AM - 11:05 AM | Side Keys (No Keypad) 15 11:05 AM - 11:20 AM | Adhesives; LDLs & Water Ingress 10 11:20 AM - 11:30 AM | PS&C* 10 11:30 AM - 11:40 AM | Field Service* 10 11:40 AM - 11:50 AM | Manufacturing and GNPO Items * 10 11:50 AM - 12:00 PM | Wrap-Up & Closing *

Product Overview – Requirements Drop Requirement: 48” to concrete Mech. Cycle Life Requirements: 40k cycles for buttons 5k cycles for connectors Operating Temp. Limits: -10°C to +60°C (due to embedded battery) Storage Temp. Limits: -40°C to +85°C Unique Test Requirements or Deviations: Product will generally follow the DVT test flow with changes made for the integrated battery (change specifics?) Target of IEC IP54 or IP55 rating for water & dust ingress resistance (minimum requirement of IPx4). Material Selection: Est. Yearly Volume: 800k over 9 months Tol. Analyses Status: IN PROGRESS Database Status: FEA Status: 1) IN PROGRESS 2) REVIEWED - NOT APPROVED 3) APPROVED 4) N/A - CONCEPT REVIEW

Exploded View

Cross-sections Overall Dimensions: 46.6 x 46.6 x 9.6 mm

Cross-sections

Housings / Accessories Main Housing Front Chassis uUSB Grommet Wrist Band Simple Clip HSJ Connector

“G2” – Main Housing (Overview) Supplier: Foxconn, BYD, or JGP Main Housing Molded plastic (EXL1414?) Painted Graphite Grey 55% gloss Integrated Light Pipe Similar to a keypad design, mold clear or translucent plastic -> black base coat and grey paint -> laser etch paint to reveal plastic as needed -> clear top coat Metal Back Stainless Steel (Type?) Laser etched batwing and tech marks High polish finish (Clear coat needed?)

“G2” – Main Housing (Attachment) Multiple options have been proposed, but the current direction is as follows: Design an undercut in the plastic ~25mm on each of the 4 sides and a matching 0.7 x 0.3 protrusion in the metal as shown to act as a snap feature and increase part bonding Apply adhesive to the metal surface around the entire perimeter to provide both part adhesion and water ingress resistance Press the two parts together and rely on the 4 walls of the plastic to flex outward and over the snap features

“G2” – Main Housing (Plastic) Proposed exterior slide motion shown with witness lines in the 4 corners Proposed lifter design shown to create the snap and button features The individual lifters shown may be combined into one large one for each of the 4 sides depending on the final direction of the attachment solution

“G2” – Main Housing (Metal) Machined part Primary surface is 0.3mm thick Perimeter walls are 1.2mm wide by 2.7mm tall One (possibly two) M1.4 screw bosses as shown Proposed housing attachment detail on 4 sides is 0.7 wide x 0.3 tall x ~25mm long

“G2” – Lens Chassis (Overview) Supplier: Molex Co-molded part which: Holds the Display / Lens assembly to the main housing Provides a perimeter water-ingress seal Holds the LDS antenna Part attaches to main housing via 7 snap features Materials: Xantar C RC (PC/ABS)

“G2” – Lens Chassis (Water Seal Feature) Material: Kraiburg TPE Thermolast K (50, 60, or 70 Shore A) Proven to be able to survive the LDS plating bath Two design profiles are being considered (Straight “Wipe” and “T”) Concern about fill and strength due to thin cross-sections (0.35 + 0.30 + 0.35 = 1mm) 1mm

USB Grommet design Once assembled the retention features hold the grommet in place preventing accidental dis-assembly. USB hole seal Tail is pulled through the hole and then snipped. The hole acts as a visual indicator for trimming after the tail is pulled in.

Wrist Band Watch band will have rails in 3 sides to hold the unit in place.

Construction The goal is to mold the plastic part in the center. Follow up with an insert 2 shot over mold process. The snap feature shown is just a place holder for now. The 3 piece construction will be made into 1 piece metal snap. Metal snap will be a zinc die cast part followed by machining.

Simple Clip 2 piece clip assembly Plastic frame Spring metal clip Materials: Plastic frame: EXL 1414 Spring clip: SUS 304, ¼ hard , polished Al 6061, ½ hard, anodized Spring metal stamping and geometry being investigated. Challenges in precise and tight bend controls along the hem and lifter movements at the corners on the plastic frame. Supplier: Chicheng??

HSJ – Designed in features Silicone gasket has O-rings designed in two seal to the front and the bottom of the connector Alignment features that constrain in x,y,z

Assembly

Connectors/Contacts/PCBs/Flexes Main PCB Secondary PCB Side-key Flex Touch Flex Display Flex Jumper Flex HSJ Flex

G2 PCB-A 0.7 (or 0.8?) mm thk. (8 or 10 layers) Flangeless µUSB – 09014162002 Secured to main housing by M1.4 screw 1.5mm Board-Board Connectors 30 or 24pin 60pin Battery Connector – 3-pin, (Molex:78171-0003)

G2 PCB-B 0.5mm PCB (or Rigid Flex?) mm thk. 1.5mm Board-Board Connectors 30 or 24pin 60pin Screw to secure board most likely disappearing due to lack of clearance space on PCB-A. Alternate method for holding PCB-B has not yet been identified Jumper Flex ZIF – 0971091G06 HSJ Flex ZIF – 0971327T01 Side Key ZIF – 0971091G09

Side Key Flex Assembly (Mflex) 2.3N Tactile Switch 0971091G09 15-pin ZIF Connector 0.15mm Stainless Steel Stiffeners Flex Service Loops

Side Key Flex (2-Layer) Flat Pattern (Mflex) 79.35 13.52 1.60 The small distance between switch flex pad and edge of flex will require solder mask in these areas (rather than typical coverlay openings).

Touch Flex with tri-color LED 44.13 5.25 (preliminary) 23.47 TOUCH FLEX – FLAT STATE Touch Flex with tri-color LED 23.20 Touch Flex ACF bonded to touch sensor Display Flex: 2 layer flex, 0.15mm thick 17 lines, ZIF connector termination ZIF connector: 0971091G0* (17 pins) (Molex P/N 502250-1791) Supplier: TBD

Display Flex Display: 1.6” QCIF TFT 35.70 x 34.30 x 1.64 mm frame size. 31.68 x 25.34 mm Active Area. Display IC on the top when assembled. Supplier: AUO Display Flex (preliminary): Part of the display assembly. 2 layer flex, 0.13mm thick. 21 lines, ZIF connector termination. ZIF connector: 28009257001 (21 pins) (Molex P/N 502078-2110) Supplier: AUO Display Flex: Backlighting LED: 4 Gold pads on bottom side.

Jumper Flex Jumper Flex Assembly: 39.9 11.0 12.30 15.5 Jumper Flex Assembly: Intermediate flex to connect display and touch flex to the bottom PCB. Flex connectors are 17 pin (touch) and 21 pin (display) ZIF connectors mounted on jumper flex. Rests on top of PCB memory IC top surface for layout 2 layer flex, 0.15mm thick. 38 lines, ZIF connector termination on PCB side. ZIF connector on PCB side: 0971091G06 (Molex P/N 502250-3991) ZIF connector for touch flex: 0971091G0* (17 pins) (Molex P/N 502250-1791) ZIF connector for display flex: 28009257001 (21 pins) (Molex P/N 502078-2110) Supplier: MFlex

Flex assembly Flex will have .05mm conductive adhesive - 3M_9725 In addition to rounds on 3 corners for alignment, there is a dedicated alignment tab The flex with the adhesive is adhered to the corner. Spring contacts on the connector make connection to the flex. Connection options to the main board: The flex may be connect to via a zif connector (Mot p/n 0971327T01) The flex may also be hot-bar soldered to the btm board If the btm board is rigidized flex, then the hsj flex can be a branch of it

Lens/Cap-Touch Main Lens Sensor Stack

Lens Overview Glass Lens OCA Display: 1.6” QCIF Display Flex Touch Flex CROSS SECTION ITO Stack (Film Sensor)

Touch Sensor Display Flex: 2 layer flex, 0.15mm thick Touch flex wraps around the display to route on the display back side to make ZIF connection Touch Flex with tri-color LED Touch Flex ACF bonded to touch sensor Display Flex: 2 layer flex, 0.15mm thick 17 lines, ZIF connector termination ZIF connector: 0971091G0* (17 pins) (Molex P/N 502250-1791) Supplier: TBD

ALTERNATE ITO STACK WITH SHIELD Sensor Stack G2 ITO STACK OCA1+ITO(Y) 0.055 OCA2 0.05 ITO(X) OCA3 0.10 ITO SHIELD TOTAL 0.305 ALTERNATE ITO STACK WITH SHIELD OCA1+ITO(Y) 0.055 OCA2 0.05 ITO(X) OCA3 ITO SHIELD 0.10 TOTAL 0.305 ITO SENSOR STACK WITH SHIELD: ITO shield needed to isolate display noise from direct sensor lamination. Display LCD is a line inversion type with AC Vcomm. 2 layer ITO film sensor + 3rd layer ITO shield. Prospects for ITO shield to be 0.10mm if low resistance ITO (140 ohm/square range) is needed Sensor ACF bonded to touch flex. Silver trace ring along ITO film perimeter for added shielding. Supplier: AUO ITO SENSOR STACK: 2 layer ITO film sensor Sensor ACF bonded to touch flex Silver trace ring along ITO film perimeter for added shielding Supplier: AUO

Lens Edge Finish Glass Lens: 44.0 x 44.0 x 0.70mm Gorilla glass. Lens chamfer under study 1. 0.50 x 0.60 mm Glass Lens: 44.0 x 44.0 x 0.70mm Gorilla glass. Second surface lens decoration, including back key (touch button). Supplier: TPK Solutions 2. Larger chamfer 3. Full edge radius (liquid pool appearance) OCA: Direct display lamination to the touch sensor. 0.20mm, 3M 8188.

Lens Chassis Adhesive Lens-Chassis-Adhesive: Bonds the lens stack to the plastic chassis framework. Part of the lens-sensor stack assembly, comes pre-assembled with the lens assembly. Min. width: 1.90 mm (top side) Width across ALS opening .52mm, any material there is OK. Thickness: 0.20mm, may change with changes to ITO stack. Material: Nitto Denko 57120W Convertor: TPK Solutions

Lens Drawing

Side Keys

Side Keys CMF Workout Key Power Key Volume Up / Down Keys Music Key

Round Key (Front Loaded Design) Part Description Material Finish Supplier Side Key, Round 5000 Series Aluminum Anodized Chi Cheng The preliminary cosmetic material and finish are as follows: Micro-machined 5000 series aluminum (overall size and detailed key features) Spun front face Laser etched or machined icons (graphics) Graphite Grey anodize Full polish The cosmetic material and finish of the key needs to be higher quality. Cosmetic flat surface and edge chamfer detail Retention snap feature on back side of key

Oval Key (Front Loaded Design) Part Description Material Finish Supplier Side Key, Round 5000 Series Aluminum Anodized Chi Cheng The preliminary cosmetic material and finish are as follows: Micro-machined 5000 series aluminum (overall size and detailed key features) Spun front face Laser etched or machined pattern Natural anodize Full polish The cosmetic material and finish of the key needs to be higher quality. Cosmetic flat surface and edge chamfer detail Retention snap feature on back side of key

Side Key Finish Options Option #1: The sides and the chamfer are one finish and the front face another Option #3: The sides, chamfer and front face all have different finishes (scale allowing) Option #4: Explore a textured side to one or more of the keys it would make sense to remove the chamfer and just have two main finish divisions Option #2: The sides have one finish and the chamfer and front face are another finish.

Front Loaded Side Keys – Sections Oval Side Key Round Side Key

Side Key : Snap Dimensions 1.17 0.50 1.50 2.67 3.00 1.00 1.35 2.50 2.85 Using similar snap features to Droid Pro except the snap is oval rather than two round snaps and the side key will be aluminum instead of EXL 1414 PC. Should we consider having less snap engagement since the buttons are metal?

Droid Pro (Venus 2) Side Key Retention Snap Features 1.20 0.13 x 70˚ Chamfer 0.48 1.38 1.46 0.88 R 0.2 0.90 These are the dimensions for the Droid Pro (Venus 2) side key retention snap and corresponding housing detail.

Side Key Water Seal Part These areas are for the plunger and switch and need to be free of deformation. Cannot have gate or cavity marking. Sheetmetal Retention Barb Features Part Description Material Finish Supplier Metal Insert 0.15mm Thick, 304 Stainless, ½ Hard - Sinco Grommet Overmold 0.40mm Typ. Thick, Silicone, Durometer 80±5 Shore A Silicon flows thru openings

Water Seal Sheetmetal Design Added holes in the sheetmetal part to allow the silicone to flow into the seal perimeter. Perhaps one of these holes or slots can be widened to be the gate area? Silicon flows thru openings

Adhesives; LDLs & Water Ingress Water seal features Keys Front to Main housing HSJ USB List of Adhesives

Side Key Water Seal Part These areas are for the plunger and switch and need to be free of deformation. Cannot have gate or cavity marking. Sheetmetal Retention Barb Features Part Description Material Finish Supplier Metal Insert 0.15mm Thick, 304 Stainless, ½ Hard - Sinco Grommet Overmold 0.40mm Typ. Thick, Silicone, Durometer 80±5 Shore A

Side Key Design - Perimeter Water Seal 2.78±0.06 2.94±0.10 4.28±0.06 4.44±0.10 Smallest Pocket Dims Largest Seal Dims Size the required gap The water seal was based on the Jordan design and has a similar 0.08mm nominal interference fit between the housing and the seal geometry (as the dimensions show, this would result in a line-to-line condition with the smallest seal and largest housing opening).

Deformed Silicone Material Volume Since silicone is incompressible, the silicone interference fit needs to be accounted for by allowing there to be space for this material to be compressed.

“G2” – Lens Chassis (Water Seal Feature) Material: Kraiburg TPE Thermolast K (50, 60, or 70 Shore A) Proven to be able to survive the LDS plating bath Two design profiles are being considered (Straight “Wipe” and “T”) Corner behaviour may be different than along the edges 1mm

HSJ Connector : Seal between plastic and gasket Pegs fit into undercut in housing to provide z-compression With the current design, the two indicated flat surfaces touch create the water seal. If that does not work, we could add o-ring to the gasket as a steel safe change to increase the chances of water seal

Water seal – TA’s TA-3 TA-1 TA-2 O-rings seal in the front and the bottom side. TA-3 TA-1 TA-2

TA-1

TA-2

TA-3

Water seal XY – Cross section Z – Cross section The grommet has a .05 mm interference all the way around the USB opening and the tail opening.

Attachments and Adhesives Part Adhesive Material Thickness Min. Width Mating Surface “A” Mating Surface “B” Battery Adhesive Tesa4982 or Nitto 5610 0.10 mm n/a Battery Shrink wrap S.S. Main Lens Adhesive Nitto Denko 57120B 0.2 mm 1.9 mm PET EXL1414 HSJ Flex Adhesive 3M 9725 0.05 mm Polyimide Display Adhesive 3M 8188 0.20 mm Glass Flex/Stiffener Tatsuta CBF-300 0.04 mm

PS&C DV Test Plan MDu 04 MDu 11 MDu 13 MDu 14 MDu 20 MDu 21 MDu 22 Threaded Fasteners Torque Retention MDu 11 Contact Height Post - Environmental MDu 13 Touch Screen Stress Test MDu 14 Particulate Motility Test (PMT) MDu 20 I/O Connector: Linear Insertion Cycling MDu 21 I/O Connector: Rotational Continuity MDu 22 I/O Connector/Audio Jack: Accsy Plug Drop MDu 23 I/O Connector: Sideload Durability Cycling MDu 25 I/O Connector: Push/Pull Strength MDu 26 Audio Jack Connector Interface MDu 27 Audio Jack Connector Transverse Load MDu 28 Audio Jack Insertion Load Robustness MDu 29 Connector Covers Retention MDu 30 Infra Red Imaging MDu 31 Side button Life Cycling MDu 33 Keypad and Button Robustness MDu 39 Lens Scratch Resistance and Hardness MDu 40 4 ft. Steel Plate Drop Test MDu 42 External Lens Scratch Resistance MDu 44 Shield and PC Board robustness MDu 51 Impact Exterior Surfaces MDu 52 Environmental / Chemical Susceptibility MDu 53 Accidental Water Intrusion Resistance MDu 54 Pressure Fault Test MDu 56 Abrasion Resistance Test MDu 57 Decorated surfaces test MDu 58 Purse Test MDu 59 First Surface Finishes - Paint Adhesion MDu 60 Pencil Hardness MEr 03 Keypad/Button Tactile Response MEr 04 Ergonomic Tests MXc 01 Sine vibration MXc 04 Salt Spray (mobiles) MXc 05 Water Ingress Certification MXc 06 Tumbler Test MXc 15 Solar Radiation for PQE Certification

Field Service

GNPO & Manufacturing