1. G2 3D Design Review

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

3. 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

4. Exploded View

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

6. Cross-sections

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

8. “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?)

9. “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

10. “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

11. “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

12. “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)

13. “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 ( = 1mm)
1mm

14. 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.

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

16. 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.

17. 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??

18. 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

19. Assembly

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

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

22. 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 – G06
HSJ Flex ZIF – T01
Side Key ZIF – G09

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

24. 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).

25. 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:
G0* (17 pins) (Molex P/N )
Supplier: TBD

26. Display Flex Display: 1.6” QCIF TFT
35.70 x x 1.64 mm frame size.
31.68 x 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: (21 pins)
(Molex P/N )
Supplier: AUO
Display Flex:
Backlighting LED: 4
Gold pads on bottom side.

27. 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: G06 (Molex P/N )
ZIF connector for touch flex: G0* (17 pins) (Molex P/N )
ZIF connector for display flex: (21 pins) (Molex P/N )
Supplier: MFlex

28. 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 T01)
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

29. Lens/Cap-Touch
Main Lens
Sensor Stack

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

31. 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:
G0* (17 pins)
(Molex P/N )
Supplier: TBD

32. 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

33. Lens Edge Finish Glass Lens: 44.0 x 44.0 x 0.70mm Gorilla glass.
Lens chamfer under study
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.

34. 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

35. Lens Drawing

36. Side Keys

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

38. 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

39. 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

40. 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.

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

42. 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?

43. 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.

44. 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

45. 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

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

47. 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

48. 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).

49. 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.

50. “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

51. 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

52. 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

53. TA-1

54. TA-2

55. TA-3

56. 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.

57. 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

58. 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

59. Field Service

60. GNPO & Manufacturing