PEM Europe Introduction - pemnet.com angle fasteners that are encased into the monitor plastic. A...

© 2014 www.pemnet.com 1

iPhone 6

2015-Feb-19

by MJM

PennEngineering®

Title Slide – Do Not Remove Enter the Name and Model of the object being torn down.

If it is CSI, leave the Confidential note.

If it is a teardown, remove the confidential note, delete the CSI logo.

http://www.pemnet.com/


iPhone 6

Introductory Slide – Do Not Remove Enter the name of the object being torn down

and a picture of the assembled product.



Details & Findings

Pictures and Description of the

iPhone 6 and our disassembly

process.

Section Heading Slide – Do Not Remove Enter the Name of the object being torn down.



Detaching the Screen

Detail Slide – Copy and use for details. Title various slides to correspond with different

portions of the object being torn down (e.g.

Case, charging station, etc…)

• M1 x 4 mm overall length

• 1.5 mm head diameter

• .4 mm head thickness

• Gold Dye per the phone color

• Nylon locking patch

Two M1 screws with 5 lobe security

drivers are removed from the bottom of the

phone. These screws engage two die cast

right angle fasteners that are encased into

the monitor plastic. A soft gasket cover is

placed over each of the right angle fasteners.

This may serve as a shock inhibitor.


© 2014 www.pemnet.com


5

With the pentalobe screws removed from the

bottom of the phone, a suction cup is now used to

pull the bottom of the monitor off of the phone case.

Plastic hooks at the top of the monitor engage a lip in

the phone case as is shown above.




6

A set of hooks are connected into each side of the phone

case as is shown in the lower photo above. These hooks engage

loops that are attached to the screen shown in the upper photo

above. The hooks are backed up by a springy substance that is

compressed between the phone case and the hooks themselves,

and serves to keep pressure on the hooks into the loops. This

fastening system keeps the edges of the case and monitor firmly

held in place. The hooks are held in place by screws that engage

rectangular clinching fasteners similar to a R’Angle®.

Loops

Hook Clips




7

• M1.2 x 2.2 mm overall length

• 2 mm head diameter


•. Stainless Steel or Zinc Plated


The fastener to the left is a clinching

insert that is pressed into the channel shown.

When the screw is tightened, it puts the web

of the channel into compression, creating a

very sound clamp load for the clips attached

to the sides. This is an improvement to the

overall connection since; 1) the possibility of

damaging the cosmetic surface due to screw

tightening is eliminated, and 2) because the

fastener is installed at 90 degrees to the

direction that the fastener is clinched, the

fastener itself can not be pulled out by screw

tightening, 3) a clamping of the walls of the

slot occurs when the screw is tightened, which

adds significant strength to the clip

connection. The monitor clips and all external

switches are held on in this manner.



Disconnecting the Screen Ribbons

8

Five Phillips head screws are removed from a shield

which holds four ribbon cables in place from the monitor to

the processing unit.




9

• The screw to the left is used in

the Red, Green, Purple, and

Yellow locations.

• M1 x 1.2 mm overall length



• Zinc plated steel or stainless

steel


• The screw to the left is used in

the Blue location.

• M1.2 x 3 mm overall length



• Zinc plated steel or stainless

steel





10

• Surface mount bushing circled in Blue

• 2.6 mm outside diameter

• 1.6 mm Inside diameter

• .8 mm Tall

• Helix knurled exterior

• Surface mount standoff circled in

Green, Purple and Yellow


• 2.7 flange diameter

• M1 internal thread

• .5 mm Tall

• Helix knurled flange

• Coupling Screw circled in Red

• M1 internal thread in head

• M1.2 external screw thread

• 2.25 mm overall length


• .73 head height

• 1.6 mm shoulder diameter

• .4 mm shoulder height




11

The two assembly stacks shown here detail the

connection from the screen ribbon retaining cover

through to the aluminum case, where clinching

threaded inserts are installed.

This M1.2

clinching insert

is detailed on

the following

slide.



The M1.2 Clinching Threaded Insert

12

M1.2 Threaded Insert Section

The photo above depicts a section of

the M1.2 threaded insert whose geometry

was designed in 2011 as drawing to the

right suggests. The section shows some

underfill in the undercut on the right hand

side of the photo.



Disconnecting the Battery

13


• 2.16 mm head diameter.


• Stainless Steel or Zinc Plated







After the retaining plate is

removed, the battery is

disconnected.




14

The photos to the left illustrate

the assembly stack of the two

screws shown on the previous

page. The left most screw

crosses through a surface mount

standoff which is identical to the

one detailed on slide #10. Both

screws terminate into clinching

inserts that are detailed on slide

#12.




15

The battery is held in

place with two strips of

double sided tape similar

to “Dow Command

Strips®”. Once the ends of

the strips are pried up, the

resulting tabs are used to

stretch the tapes to

disengage them, releasing

the battery.



Removing The Camera

16

• M1x 1.2 mm overall length





• M1x 1.5 mm overall length

• 2 mm head diameter.




Two screws, pictured below, are removed to detach

a cover which retains the rear facing camera. The

ribbon of the camera itself must be lifted first to expose

the upper left screw. The screws engage holes tapped

directly into the phone case.



Small Ribbon Connector under Camera

17

• The screw to the left is used in the location

shown circled in Red




• Zinc plated steel or stainless steel


• Surface mount standoff circled in Blue


• 2.7 flange diameter

• M1 internal thread

• .5 mm Tall

• Helix knurled flange

One screw remains in holding a small ribbon cable between a camera contact point and a standoff on

the main board. This is the same screw and standoff as detailed on slide numbers 9 and 10.



The Flash Retaining Shield

18

Two screws

are removed to

detach the bracket

shown above, while

a third screw shown

to the left is

removed to fully

detach the flash

retaining shield.

See slide # 16



The Flash Retaining Shield

19











This M1 clinching insert is

detailed on the following

slide. This M1.2

clinching insert is

detailed on slide

#12

This M1.2

clinching insert is

detailed on slide

#12

• M1.2 x 1.5 mm

overall length

• 2 mm head

diameter

• .3 mm head

thickness

• Zinc plated steel

or stainless steel

• Nylon locking

patch



The M1 Clinching Insert

20

The photo above depicts a section of

the M1 threaded insert whose geometry

was designed in 2011 as drawing to the

right suggests. The section shows some

underfill in the undercut.

M1 Threaded Insert Section



Connector Retaining Plate Removal

21













Connector Retaining Plate Removal

22

The assembly stack to the left shows why the

different length screws are required for this one

shield. The shield is also stamped to different

heights at the hole locations to accommodate the

difference in height created by the sandwiching of

the plastic antenna mount. An alignment pin can be

seen in the stack on the left. The screws engage

two clinching inserts detailed on slide # 12.

Locating Pin



The Antenna

23






• Circled in Red






• Circled in Yellow

Four screws as described below

are removed to release what might

be part of an antenna

A B

C D



The Antenna

24

The short screws to

the left attach the

antenna piece to the

board level. The far left

screw enters a clinching

insert as is detailed on

slide # 12. This insert is

pressed into a

cantilevered protrusion in

the phone case as is

shown. The second

screw from the left

enters a surface mount

standoff that is soldered

to the board (detailed on

the following slide). The

two screws on the right

attach to the case level

(below the board), into

two more clinching

inserts like the ones

detailed on slide # 12.

A B C D



The Antenna

25

• Surface mount standoff, circled in

Red


• M1.2 internal thread

• .2 mm Tall

• Surface mount standoff , circled in Green


• M1.2 internal thread

• .5 mm Tall

• Helix knurled exterior

• M1.2 x 1.5 mm overall length, circled

in Blue





The surface mount standoff discussed on the previous slide is detailed below and to the left. Two screws, circled in Blue are

removed to release a strap which connects the board to an isolated portion of the phone case. The upper screw of this strap enters

another insert as detailed on slide # 12, and is cantilevered. The lower screw enters a surface mount standoff as is detailed in the

lower right.



More Antenna

26

• M1.2 x 1.5 mm overall length,





One screw as is detailed above

and on slide # 21 is removed from

the board level. This screw enters

another clinching threaded insert as

is detailed on slide # 12



Board Locating Connection

27






Board Locating Connection

• M1.2

• 2.15 mm OD X .4 tall raised barrel

The removal of a screw as detailed above and

the removal of the SIM card as shown to the left,

release the phone control card from the housing.

The raised portion of the clinching insert above

enters a counter bore in the bottom of the card.

This and a locating pin (shown on slide # 22) near

the top of the phone locate the card precisely within

the phone case.



The M1.2 Locating Insert

28

The section of the part shown above illustrates that

this is very similar to the part shown on slide #12 (M1.2

insert) with the addition of a locating collar on the top.



The SIM Card Ejector

29




• 1.75 mm shoulder dia.

• .42 shoulder height



See slide # 20

The SIM card tray ejector is held in place with the shoulder screw detailed above. The M1

clinching insert which it engages is detailed on slide # 12. I believe the difference in appearance is

that this fastener was not masked prior to anodizing as was the part shown on slide #’s 18, 19 and

20.



The Vibrate Motor

30






M1.2 insert. See slide # 12

Two screws as detailed to the left are removed to

release the vibrate motor. A locating pin in the left side

of the mount of the motor, locates the part precisely.



The Big Speaker

31











Four screws are removed to release the main

speaker from the housing. Three of the screws

engage the M1.2 clinching fastener which is detailed

on slide # 12, while the screw circled in yellow is

installed into a tapped hole.



Some Antenna Connections

32






Two screws, detailed

to the far left, are removed

to detach connections

between an isolated part

of the phone case and

some flexible circuit

attachments. These

screws enter tapped

cantilevered holes as

shown immediately left.



The Data / Charging Port

33



• 1.5 mm shoulder length







The Data / Charging Port

34






Removal of the two screws shown

to the left releases the Lightning port

from the case, but not from the flex

circuit below it.



Small Speaker Backer

35








The part shown to the

immediate left appears to

be a dampening device

mounted behind a small

speaker. It is held in place

by the shoulder screw

shown to the left and a

locating pin (in the smaller

hole).



The Earphone Jack

36






The two screws detailed to the left are

removed to detach the earphone jack.



The Phone Case

37

10

24

2

1

3

M1.2 insert detailed on Slide # 12


M1 insert detailed on Slide # 20


M1 Tapped holes

3 M1.2 Tapped holes



The Phone Board

38

1

1

2

4 Surface mount standoff detailed on slide # 10

Surface mount standoff detailed on slide # 10





The Monitor

39



The Caller Facing Camera and Ear Speaker

40
















Removal of the

three screws detailed

above releases what

might be a processing

unit for the caller facing

camera.



The Caller Facing Camera and Ear Speaker

41

The two screws shown to

the left (detailed on the

previous slide) engage two

molded in threaded inserts

shown below.



The Home Button

42






• M1 mm molded in threaded insert

• 1.8 mm diameter raised ring.


Two screws

are removed to

release the

home button as

shown.

• 1.9 mm dia.

• .65 dia. Button

• .54 height

• .35 flange thk.

• SS or Plated



Stainless Shield

43


• 1.7 mm countersunk head diameter.

• .2 mm head height, including ramp








Seven screws are removed as

shown to release the stainless

steel monitor shield.



The Monitor Back / molded in inserts

44

• Molded in insert




• Molded in / weld in inserts



• 2 mm shoulder dia., .15 high




• 1.5 mm shoulder dia., .15 high





Fastener Summary

Section Heading Slide – Do Not Remove



The Screws

Detail Slide – Copy and use for details. Create a table of the fasteners found in the teardown.

Note thread sizes, lengths, drivers, etc. Multiple pages

can be used for different style fasteners




• Gold Dye per the phone color


• Quantity 2

• Slide # 4






• Quantity 13

• Slide #’s 7,18,19,21,22,31






• Quantity 7

• Slide #’s 9,11,13,14,21,22,31,36






• Quantity 7

• Slide #’s 9,11,16,17,18,19

• Coupling Screw M1 internal thread in head

• M1.2 external screw thread

• 2.4 mm head diameter, 2.25 mm overall length


• 1.6 mm diameter shoulder

• .4 mm shoulder height



• Quantity 1

• Slide #’s 10,11






• Quantity 1

• Slide #’s 13,14



The Screws









• Quantity 2

• Slide #’s 16,43






• Quantity 11

• Slide #’s 18,19,23,24,25,26,32,34






• Quantity 2

• Slide #’s 23,24






• Quantity 3

• Slide #’s 27,30






• Quantity 1

• Slide #’s 40,41




• 1.75 mm shoulder dia.

• .42 shoulder height



• Quantity 1

• Slide # 29



The Screws









• Quantity 4

• Slide #’s 40,41,42






• Quantity 1

• Slide #’s 43


• 1.7 mm countersunk head diameter

• .2 mm head height, including ramp



• Quantity 6

• Slide #’s 43






• Quantity 3

• Slide #’s 33,35



Clinching Fasteners (Female Thread)

49

• M1.2 clinching threaded insert

• __ mm across knurl diameter

• __ mm flange thickness

• __ mm overall length

• May be Titanium

• Quantity 24

• Slide #’s 11,12,14,19,22,24,26,29,30,37

• M1.2 clinching threaded right angle insert

• 2.2 mm body width

• 1 mm body thickness

• 2.82 mm flange length

• .5 mm flange thickness

• 2.3 mm overall length

• May be Titanium (not magnetic)

• Quantity 10

• Slide #’s 7,37

• M1 clinching threaded insert




• May be Titanium

• Quantity 2

• Slide #’s 19,20,29,37

• M1.2 clinching threaded insert

• 2.15 mm dia. x .14 mm tall raised section




• May be Titanium

• Quantity 1

• Slide #’s 27,28,37



Surface Mount Fasteners (Female Thread)

50

• M1 Surface Mount Standoff

• 2.2 mm flange diameter / helix knurls

• .5 mm tall

• Quantity 4

• Slide #’s 10,38

• Through hole Surface Mount Standoff

• 2.6 mm OD / helix knurls

• 1.6 mm ID

• .8 mm tall

• Quantity 2

• Slide #’s 10,11,13,14,38

• M1.2 Surface Mount Standoff

• 2.2 mm OD

• .2 mm tall

• Quantity 1

• Slide #’s 25,38

• M1.2 Surface Mount Standoff

• 2.5 mm OD Helix Knurled flange

• .5 mm tall

• Quantity 1

• Slide #’s 25,38

Forged Button / Under Home Button

• 1.9 mm OD

• .65 diameter button

• .54 Overall height

• .35 flange thickness.

• SS or Plated

• Quantity 1

• Slide # 42



Molded in Fasteners (Female Thread)

51





• Quantity 3

• Slide # 44

• Molded in / weld in inserts



• 2 mm shoulder dia., .15 high


• Quantity 2

• Slide # 44



• 1.5 mm shoulder dia., .15 high



• Quantity 1

• Slide # 44



Alternate Solutions

PennEngineering® recommendations

of alternate hardware and cost savings

opportunities.




Alternate Solutions

Detail Slide – Copy and use for details. Note any new solutions (PEM or non-PEM).

Highlight the advantages and disadvantages

of each.

PennEngineering® is fully capable of making all of the fasteners shown on slides 46 to 51. Our

experience with forging and materials as well as expertise with self clinching fastener design enable us

to provide a superior solution for the fasteners shown on slide #49 (self clinching inserts). These self

clinching inserts may be more effectively manufactured on forging equipment, and consequently result

in a cost savings and throughput improvement.

In addition to direct replacement and perhaps some manufacturing and material substitution for

functional and cost improvement, some alternate fastening suggestions are presented for specific

situations on the following slides.



Monitor Edge Snaps

54

Loops on Screen

Clips shown not

attached to phone

case for clarity

The clips shown in the photos above illustrate the

monitor fastening solution for the left and right edges of the

monitor. The top of the monitor is held by molded in clips

(slide #5) and the bottom is held by right angle fasteners and

screws (slide #4). A possible alternative to the clips depicted

above and the advantages are discussed on the following

slide.

A lot of battery side space is

dedicated to the monitor

fastening system.



Monitor Edge Snaps

55

The iPhone 6 monitor is intended to be

removed by pulling up on the bottom edge after

the pentalobe screws are removed. As such it

opens with an arc shaped motion. The

rectangular clips are not however oriented to be

engaged in this motion. Full disengagement

happens for the clips closest to the bottom of the

phone first. The result is that the monitor

requires the highest force to open when all the

clips are engaged. Since the clips closest to the

home button disengage first, the force to open

the monitor drops quickly, which can cause a

jerking action when the clips release. This action

puts the ribbon cables at top of the phone in

danger if a tool such as is shown in the photo

(which limits the extent of the motion) is not used

for this operation.

The clips described on the following slide

describe a more versatile attachment.



Monitor Edge Snaps

56

Monitor edge snaps

engage, by snapping

on and off of the

horizontally installed

TackPin®

These clips take less space inside the case and

can be installed anywhere along the edge of the

phone where there is room to install just one tack

pin. Vertical clearance below the tack is also

increased, creating space for more circuitry, or a

larger battery.

In addition to the benefits mentioned

already, this solution simplifies the

design by replacing two screws, two

right angle clinching fasteners, and one

folded metal clip with one tack pin,

wherever fixing is required.

Clip, stamped

into monitor

sheet metal.

Clip opening can be designed so that it is

oriented with the arc radius at the clip point



M1.2 Clinching Inserts

57

iPhone 6 Pull Out Data

YA7-31720 Thread Stripping due to pull out

This fastener was originally designed and quoted

by PennEngineering, as shown to the right.

234 N average



The M1 Clinching Insert

58

This fastener was originally designed and quoted

by PennEngineering, as shown to the right.



The Surface Mount Parts

59

The surface mount hardware (slide 38) shown on the phone controller could be interchanged

either with PEM® standard product or specials.



Replace the Coupling Screw with the Configuration Shown on the Right

60

The two assembly stacks shown here detail the connection from

the screen ribbon retaining cover through to the aluminum case,

where clinching threaded inserts are installed. The stack height

and connected elements are the same.

This M1.2

clinching insert

is detailed on

the following

slide.

Replace the Coupling Screw with the Configuration Shown on the Right



Soldering to Glass

61

Future designs may benefit from our

capability to solder fasteners directly to the glass

of the monitor.



Replace the Shoulder Screw with a Large Headed TackPin® installed

into a boss- solution 1

62



Fig.3

We herein present an alternative more efficient solution to the

current SIM card ejector design. The new design involves the

use of a Tackscrew to join a SIM tray lever to the plastic tray that

holds the SIM card. For more details, please contact the New

Product Development Engineering group at PEM.

SIM tray lever

SIM tray

lever SIM tray lever

New Design

Replace the Shoulder Screw with a Large Headed TackPin® installed

into a boss- solution 2



Conclusions and Summary




Conclusion

Detail Slide – Copy and use for details. Summarize the findings and alternate

solutions.

The iPhone 6 is as expected a beautiful phone. As is typical with Apple’s phones many threaded

fasteners are used in it’s construction. PennEngineering® may be able to help with fastener

standardization, assembly simplification, cost reduction, and overall product improvement, with the

implementation of some of the alternative fastening solutions suggested.

As was stated earlier, PennEngineering® can produce any of the fastening solutions used in the

phone, within our current manufacturing facilities. Our design and manufacturing expertise may create

cost savings opportunities alone.

Beyond direct replacement there are other improvement possibilities. The hardness of the phone

case was measured to be HRB 40. This is relatively soft, making an insert made from 2024-T4

capable of being clinched. As the data presented in this report shows, the pull out force for the actual

inserts used is significantly lower than the stripping strength of an insert made from 2024-T4 aluminum.

Advantages of 2024-T4 aluminum over the titanium that is currently being used are:

• No electrical potential between the fastener and the case

• No masking of the fastener would be required during the anodization process as is

required with the Titanium

• 2024 aluminum is heat treated after forming to give it a high hardness and strength. Because

it is more workable in it’s soft state than Titanium, tools last longer and production rate is

increased. Both factors lend themselves to lower cost to manufacture than Titanium.

The side clips for the monitor might be replaced with a TackPin® and snap solution as is described

in slides 54-56.



Conclusion

66

The coupling screw described in slides 11 and 60, might be eliminated with the use of another

surface mount standoff as is shown on slide 11.

The use of surface mount technology that is used on the circuit board may also lend itself to future

innovation by soldering PEM® fasteners directly to the monitor glass.

Finally the use of one large headed tack pin installed into a boss in the case could replace a

custom shoulder screw and a threaded insert .


PEM Europe Introduction - pemnet.com angle fasteners that are encased into the monitor plastic. A...

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