Abstract:
A complex geographical edge finishing system includes a fixture that holds an external part having a complex three-dimensional edge, a track disposed around the fixture and surrounding the edge of the part held in the fixture, and one or more finishing apparatuses that can sand, polish, buff, paint and/or apply coatings to the complex three-dimensional edge. The finishing apparatuses move about the track such that the three-dimensional edge of the part can be polished. The path of the track can substantially match, mimic or otherwise correspond to the path of the three-dimensional edge, such that special requirements for the finishing apparatuses are not required.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 61/249,200, filed Oct. 6, 2009, and entitled “COMPLEX GEOGRAPHICAL EDGE POLISHING,” which is incorporated herein by reference in its entirety and for all purposes. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates generally to the manufacture of consumer devices, and more particularly to the automated finishing of complex edges or profiles on such consumer devices. 
       BACKGROUND 
       [0003]    New and improved consumer devices and components are constantly being introduced and provided in the marketplace. To stay competitive, designs for various consumer devices or products, such as handheld or hand manipulated devices, for example, should meet or exceed consumer expectations for numerous factors, such as cost, weight, functionality, outward appearance, texture and distinctiveness with respect to competing devices or products, among others. One industry where such considerations are particular relevant is the electronics or computing industry, although applications within many others industries can certainly apply as well. When it comes to designing, making and marketing handheld electronic devices and components, aesthetic appeal and distinctiveness can be at a premium. 
         [0004]    Particular areas that command attention from consumer product designers and manufacturers can include overall device shape and profile, as well as surface finish or texture. In many applications, relatively complex shapes or profiles for a consumer product or product component can be advantageous with respect to both aesthetic appeal and distinctiveness from the products of competitors. The shape and profile of a Coca-Cola® bottle is a classic example of a handheld consumer product that is aesthetically appealing and also distinctive with respect to counterpart items provided by the competition. 
         [0005]    Unfortunately, relatively complex shapes or profiles can limit the ability of a manufacturer to also provide a particularly desirable surface texture or finish for an outer region of such a consumer product or component. Hence, one drawback to designing consumer products having distinctively complex shapes or profiles is the ability to provide a suitably appealing surface texture or finish for the complex region or profile on the item. In particular, complex or irregular surface regions can hinder the ability to sand, polish, buff, paint, apply a coating, or otherwise provide a nice surface finish. In many cases, the use of a complex shape or profile for a consumer product, and particularly a handheld or hand operated product, can result in the need for costly and inconsistent manual finishing processes for such a product. 
         [0006]    While many designs and methods of manufacture for providing surface finishes on complex or irregular outer regions of handheld items and other consumer product components have generally worked well in the past, there is always a desire to provide new and improved designs and techniques that result in aesthetically pleasing and consistent outer surface finishes for complex surface regions of such components while also streamlining and automating the manufacturing process, such that more distinctive complex shapes and profiles can be used. 
       SUMMARY 
       [0007]    It is an advantage of the present invention to provide an automated finishing system that conducts finishing operations on a consumer product component having at least one edge with a complex profile. Such complex geographical edge polishing or finishing can be accomplished at least in part through the use of an automated finishing system that is specifically designed to account for the complex profile or profiles on the consumer product component during the finishing process. 
         [0008]    In various embodiments, an automated finishing system can include a fixture adapted to effect a hold an external part having a three-dimensional or complex edge portion, a track disposed around the fixture and arranged to be proximate to the three-dimensional edge portion when the external part is held as a result of the fixture, and one or more finishing apparatuses that include one or more rotating finishing members. The three-dimensional edge portion can defines a path that travels in each of three mutually orthogonal x, y and z directions, and the path of the track can travel in each of the x, y and z directions in a manner that substantially mimics or otherwise corresponds to the path of the three-dimensional edge portion. The one or more finishing apparatuses can move about the track such that the three-dimensional or complex edge of the part can be finished in a consistent and automated fashion. Such a finishing process can be a polishing process, although sanding, buffing, painting and other coating processes may also be used. 
         [0009]    In various detailed embodiments, the track surrounds the three-dimensional edge portion of the external part when the external part is held as a result of the fixture. In various embodiments, the one or more finishing apparatuses can include one or more rotating polishing members. The finishing apparatuses can move along the track simultaneously while the one or more finishing members or components are acting upon the three-dimensional edge portion. In various embodiments, at least a portion of the three-dimensional edge portion path includes a continuous change in each of the x, y and z dimensions. In addition, the three-dimensional edge portion path can define a closed loop, and/or can extend away from the remaining surfaces of the external part, which can be, for example, a computing device component, such as a mouse or portion of a mouse. 
         [0010]    Further finishing system components can include a tool adapted to interface with the external part to form a combined tool and external part component, wherein the tool is directly held by the fixture to result in an indirect hold on the external part. In addition, the finishing system can include a clamping component adapted to clamp the combined tool and external part component against said fixture during the finishing process. 
         [0011]    In various further embodiments, a method of finishing a consumer product component can include the steps of holding the consumer product component in or about a fixture, positioning a track around at least a portion of the fixture, disposing one or more finishing devices on or about said track, performing one or more finishing operations with the one or more finishing devices, and moving the one or more finishing devices about the track after the beginning of but before the end of the performing step. The consumer product component can have at least one edge portion with a complex profile, and this can be the part of the consumer product upon which the one or more finishing devices perform a finishing process. The track can have a particular path that reflects the nature of the complex profile edge of the consumer product component, such as a path shape that mimics the shape or profile of the complex profile edge. Again, the finishing process can be a polishing process, although sanding, buffing, painting and other coating processes may also apply. 
         [0012]    In some embodiments, the performing and moving steps are conducted simultaneously. Alternatively, the one or more finishing devices can be moved about the track in iterations, with the actual finishing processes being conducted while the devices are stopped at the various track iterations. In some embodiments, the holding step includes clamping the consumer product component against the fixture. Such clamping can be conducted during the performing step. Again, the consumer product component can be a computing device component, such as a mouse or mouse portion. 
         [0013]    In various embodiments, an apparatus can include a body having an outer surface and at least one edge portion comprising a complex profile disposed about and extending away from or rising above the outer surface. The at least one edge portion can include a surface having a finish that was provided by an automated finishing system. Such an automated finishing system can have a track with a path that reflects the nature of the complex profile edge and one or more finishing devices that move about said track as part of the finishing process. 
         [0014]    Other apparatuses, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    The included drawings are for illustrative purposes and serve only to provide examples of possible structures and arrangements for the disclosed inventive apparatus and method for providing complex geographical edge polishing. These drawings in no way limit any changes in form and detail that may be made to the invention by one skilled in the art without departing from the spirit and scope of the invention. 
           [0016]      FIG. 1  illustrates in side elevation view an exemplary consumer product having an edge with a complex profile according to one embodiment of the present invention. 
           [0017]      FIG. 2  illustrates in top perspective view an exemplary isolated complex profile edge from the consumer product of  FIG. 1  according to one embodiment of the present invention. 
           [0018]      FIG. 3  illustrates in side elevation view an exemplary automated polishing system adapted to polish the complex profile edge of the consumer product of  FIG. 1  according to one embodiment of the present invention. 
           [0019]      FIG. 4A  illustrates in side elevation view the exemplary automated polishing system of  FIG. 3  with the consumer product of  FIG. 1  mounted therein according to one embodiment of the present invention. 
           [0020]      FIG. 4B  illustrates in side elevation view the exemplary automated polishing system of  FIG. 4A  with a top clamp lowered to hold the consumer product in place according to one embodiment of the present invention. 
           [0021]      FIG. 4C  illustrates in side elevation view the exemplary automated polishing system of  FIGS. 4A and 4B  with a plurality of polishing members extended from a plurality of polishing apparatuses to polish the complex profile edge of the consumer product according to one embodiment of the present invention. 
           [0022]      FIG. 5A  illustrates in side elevation view the exemplary automated polishing system of  FIGS. 4A-4C  with the plurality of polishing apparatuses having begun to move along an associated track while polishing the complex profile edge of the consumer product according to one embodiment of the present invention. 
           [0023]      FIG. 5B  illustrates in side elevation view the exemplary automated polishing system of  FIG. 5A  with the plurality of polishing apparatuses having moved further along the associated track to a lowest position of the track while polishing the complex profile edge of the consumer product according to one embodiment of the present invention. 
           [0024]      FIG. 6A  illustrates in side elevation view the exemplary automated polishing system of  FIG. 5B  with the plurality of polishing apparatuses having moved even further along the associated track to begin ascending an upward portion of the track while polishing the complex profile edge of the consumer product according to one embodiment of the present invention. 
           [0025]      FIG. 6B  illustrates in side elevation view the exemplary automated polishing system of  FIG. 6A  with the plurality of polishing apparatuses having moved still further along the associated track and ascended along an upward portion of the track such that the polishing apparatus are tilted while still polishing the complex profile edge of the consumer product according to one embodiment of the present invention. 
           [0026]      FIG. 7  presents a flowchart of an exemplary method of finishing a consumer product according to one embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    Exemplary applications of apparatuses and methods according to the present invention are described in this section. These examples are being provided solely to add context and aid in the understanding of the invention. It will thus be apparent to one skilled in the art that the present invention may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the present invention. Other applications are possible, such that the following examples should not be taken as limiting. 
         [0028]    In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments of the present invention. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the invention, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the invention. 
         [0029]    The invention relates in various embodiments to the design and manufacture of consumer devices having complex edge or profile regions. Such consumer devices can include handheld or hand operated devices, such as portable or otherwise hand operated electronic or computing devices or components, among other suitable items. In particular, the present invention relates to the automated and reliable finishing of various complex edge or profile regions on such products. Such products can be, for example, computing device components. In a particular example, such as that which is provided herein for purposes of illustration, such products can include a computer mouse or portion of a mouse. Of course, numerous other products can have surface finishing applied as described by the systems and methods disclosed herein, and it is contemplated that such systems and methods can be used on a wide variety of suitable products and devices. 
         [0030]    Referring first to  FIG. 1 , an exemplary consumer product having an edge with a complex profile is illustrated in side elevation view according to one embodiment of the present invention. Consumer product  10  can be any of a wide variety of products, items or components, such as, for example, a handheld electronic device. Consumer product  10  can include a top  20 , a raised complex profile edge  30 , and a base  40 , among other possible components. Vertical mounting holes  41  may extend into the base  40  of consumer product  10 , and horizontal holes  42  may also extend from one side of the product to the other. In some embodiments, top  20  may be removable from base  40 , and complex edge  30  can attach to top  20  or base  40 . In some embodiments, both top  20  and base  40  can have their own attached raised and complex edge portion  30 . 
         [0031]    Alternatively, base  40  can comprise a tool that is separate from the rest of consumer product  10 . For example, consumer product  10  can comprise an inversely positioned computer mouse having a bottom portion  20 , complex raised edge  30  adapted to be gripped by a user, and an upper surface that interfaces against the top surface of the base or tool  40 . The base or tool  40  is adapted to interface with and fit loosely against the consumer product  10  to form a combined tool and product component or combination, such that the tool can be directly held by a fixture to result in an indirect hold on the consumer product, as set forth in greater detail below. 
         [0032]    Consumer product  10  is shown in  FIG. 1  with respect to three orthogonal axes, x, y and z. Complex profile edge  30  can be raised above the outer surfaces of both top  20  and base  40 , and this complex edge can form a continuous curve that does not remain constant for any significant portion with respect to any of three orthogonal axes x, y and z. That is, as one follows the path defined by edge  30 , the edge itself is always or usually varying in direction along all three axes. Such continuous or frequent multidirectional variances can result in an overall complex edge or profile of a component that can be relatively difficult to manufacture and/or to finish precisely and consistently in a mass-manufacturing setting. 
         [0033]    Turning next to  FIG. 2 , an exemplary isolated complex profile edge from the consumer product of  FIG. 1  is shown in top perspective view. As will be readily understood, complex profile edge  30  is being shown in isolation for purposes of illustration, and it is not necessary that such a complex raised edge or other complex shape or profile component be separable from consumer product  10 . For purposes of reference with respect to  FIG. 1 , an adjusted x/y/z axes indicator is also provided. Complex edge  30  can have a continuous curvature that results in one or more relatively high regions  31  and one or more relatively low regions  32 . At some or all of these regions, an outermost region  33  of the raised profile or edge  30  can be designated for one or more finishing processes. Such outermost regions  33  to be finished can exist in continuous looped fashion around an outer circumference of edge  30 . Alternatively, one or more outermost regions can be isolated or segmented (not shown) with respect to each other and/or other product components. 
         [0034]    Although the various embodiments provided herein focus on a polishing process as a finishing process of interest, it will be readily appreciated that one or more additional or separate manufacturing and/or finishing processes may be used instead of or in addition to a polishing process. Any and all such alternative processes may be accomplished though the same or similar measures set forth herein with respect to an automated polishing or finishing system. Alternative finishing processes can include, for example, sanding, buffing, painting, and applying a coating to a complex geographical edge or edge portion, among others possible processes. 
         [0035]    Moving now to  FIG. 3 , an exemplary automated polishing system adapted to polish the complex profile edge of the consumer product of  FIG. 1  according to one embodiment of the present invention is shown in side elevation view. Automated polishing system  100  can include a number of significant components, such as a specialized track  110 , a fixture  120  having one or more pins  121  or other coupling components adapted to hold a computer product to be finished, a retractable top clamp  130 , and one or more polishing apparatuses  140 . Each of the one or more polishing apparatuses  140  can include a number of components, such as a rotating polishing member  141 , a rotating support  142 , a mobile base  143 , a body  144  and an associated connector or tube  145  that can provide any of a number of things to the polishing apparatus. 
         [0036]    Polishing member  141  can be adapted to contact and polish at least a portion of a consumer product. As will be readily appreciated, a number of items can be substituted for polishing member  141  for alternative finishing applications. For example, a sanding wheel, buffing unit, paint dispenser or coating applicator might be used instead of polishing member  141 . Rotating support  142  provides support and transmits rotational energy from an internal engine (not shown) to the polishing member  141 . The entire polishing apparatus can be mounted to a mobile base  143  that is adapted to move about an associated track  110 . Body  144  can house a motor that provides rotational energy to the rotating support  142  and polishing member  141 . A flexible connector or tube  145  can be used to contain and direct various wirings and/or other materials, such as paint or another coating, to the finishing member  141  that interfaces with the consumer product. Such wirings can include, for example, power and ground for the motor, as well as a communications cable for relaying instructions from a computer system or device (not shown). 
         [0037]    Such a computer or other automated control system or device can be used to help implement the automated nature of polishing system  100 . For example, one or more computer programs and/or settings can be used to control the positioning, speed, movement and other desired factors for the functions of the polishing members  141  associated driving motors, and mobile bases  143 , among other moving parts. 
         [0038]    Of particular interest can be the specialized track  110 . While the various polishing apparatus  140  or other similar finishing devices can operate in a relatively simple and straightforward manner, the particular design of the track  110  can help to result in a finishing process having increased efficiency for a given consumer product with a complex edge or profile portion. In particular, the track  110  can be shaped or otherwise formed to have a path that reflects or substantially corresponds to path defined by the complex profile edge on the consumer product of interest. That is, the curvature or path of track  110  can mimic the curvature or path found on complex profile edge  30  of product  10 . As shown in various perspectives in  FIGS. 4A through 6B , track  110  follows a continuous curved path that is substantially similar in nature to the complex profile edge  30  that the polishing device is designed to polish. As such, a more reliable and controlled polishing process on such an irregular or complex edge or profile shape can be accomplished. 
         [0039]    Continuing now with  FIGS. 4A through 6B , automated polishing system  100  is shown in side elevation view in various stages of operation with respect to a subject consumer product  10  installed therein.  FIG. 4A  illustrates the exemplary automated polishing system of  FIG. 3  with the consumer product of  FIG. 1  mounted therein. Stage  200  reflects the state of system  100  right after the mounting of consumer product  10  to fixture  120 , but before any other components have been moved or actuated. Again, consumer product  10  can have a top  20  and a raised complex edge portion  30  that traverses the entire circumference of product  10 , while one or more polishing members  141  attached to one or more polishing apparatuses  140  can be positioned with respect to the complex edge portion. 
         [0040]      FIG. 4B  illustrates a subsequent stage  210 , with that being the state of exemplary automated polishing system  100  of  FIG. 4A  with top clamp  130  being lowered to hold the consumer product  10  in place on fixture  120 . Of course, other suitable clamping and/or affixing apparatuses or arrangements may be used to hold consumer product  10  in place for the subject finishing operation or operations. 
         [0041]      FIG. 4C  illustrates a subsequent stage  220 , with that being the state of exemplary automated polishing system  100  of  FIGS. 4A and 4B  with one or more polishing members  141  being extended from one or more polishing apparatuses  140  to polish the complex profile edge  30  of the consumer product  10 . As such, polishing members  141  actually make contact with the edge  30 , and can begin the polishing or other suitable finishing process. Polishing apparatuses  140  can then be adapted to move about track  110  such that the entire complex profile edge  30  gets polished. In the even that two polishing apparatus  140  are used, each can be designed to traverse a half rotation about the outside of consumer product  10 . At such a point, the polishing process may be deemed as finished. Alternatively, the two polishing apparatuses may reverse direction, or may continue to orbit around the consumer product in the same direction as they started. 
         [0042]      FIG. 5A  illustrates a subsequent stage  230 , with that being the state of exemplary automated polishing system  100  of  FIGS. 4A-4C , only with the plurality of polishing apparatuses  140  having begun to move along associated track  110  while remaining in contact with and polishing the complex profile edge  30  of the consumer product  10 . As shown, two polishing apparatuses  140  have both begun to traverse track  110  in a rotational direction around the outside of consumer product  10 . Although two polishing apparatuses  140  are shown for purposes of illustration, it will be readily appreciated that more or fewer such apparatus can be used. For example, a single polishing apparatus  140  can be designed to traverse the entire circumference of complex edge  30  while polishing the edge. 
         [0043]      FIG. 5B  illustrates a subsequent stage  240 , with that being the state of exemplary automated polishing system  100  of  FIG. 5A , only with the plurality of polishing apparatuses  140  having moved further along the associated track  110  to a lowest position of the track possible for the polishing apparatuses. It will be appreciated that both polishing apparatuses  140  can traverse the entire paths taken from  FIG. 4C  to  FIG. 5B  while polishing complex profile edge  30  at all times during the moving process. As shown, each of polishing apparatus  140  has progressed at or about 90 degrees of a full 360 degree circle or orbit about stationary consumer product  10 . Alternatively, one or more polishing apparatuses  140  may move some distance along the specific path of track  110  and then stop to polish a local region or portion of edge  30 . This process can then be repeated along any number of stops between the start and finish positions of polishing apparatuses  140  on track  110 . In this manner, a full polishing of edge  30  can be accomplished without performing any actual polishing when the polishing apparatuses are moving along the track. 
         [0044]      FIG. 5B  also provides particular perspective with respect to at least a portion of specialized track  110 . As shown, track  110  can include an upper surface  111  that is supported by a lower base  112 . Upper surface  111  can be formed as part of an upper flange that extends laterally beyond the sides of lower base or bottom portion  112 . Overall, the cross-sectional shape of track  110  can lend itself to the ready traversal of one or more finishing devices along its path. Again, the path of the track  110  can be specifically designed to reflect or even mimic the various properties of the complex profile or edge  30  of the device being polished or finished. By taking care to design the track in such a manner, the motion and traversal of the one or more polishing devices can follow right along with the irregular or otherwise complex nature of the edge  30 . 
         [0045]      FIG. 6A  illustrates a subsequent stage  250 , with that being the state of exemplary automated polishing system  100  of  FIG. 5B  with the plurality of polishing apparatuses  140  having moved even further along the associated track  100  to begin ascending an upward portion of the track while polishing the complex profile edge  30  of the consumer product  10  according to one embodiment of the present invention. Continuing further,  FIG. 6B  illustrates a subsequent stage  260 , with that being the state of exemplary automated polishing system  100  of  FIG. 6A  with the plurality of polishing apparatuses  140  having moved still further along the associated track  110  and having ascended along an upward portion of the track such that the polishing apparatuses are tilted while still polishing the complex profile edge  30  of the consumer product  10 . As will be readily appreciated, the polishing apparatuses  140  can then continue onward to reach a full 180 degree traversal of track  110  since the starting point shown in  FIG. 4C . In this manner, the entire complex profile edge  30  can be polished along its entirety by polishing apparatuses  140 . 
         [0046]    As will be readily appreciated, numerous additional degrees of freedom may be introduced into system  100  in order to maximize the efficiency of the automated system. For example, polishing members  141  may have a certain degree of flexibility in one or more directions with respect to their respective attached rotating supports  142 . In addition, the entire body  144  of a polishing apparatus  140  can be adapted to pivot and/or rotate about its respective mobile base  143  in a controlled manner, such that fine tuned polishing or finishing of the complex edge  30  can be accomplished. Such added degrees of freedom may be robotically controlled by an associated computer or other controller, which may be located remotely from the rest of the system, such as via connections through flexible tube  145 . 
         [0047]    Turning lastly to  FIG. 7 , a flowchart of an exemplary method of polishing or otherwise performing a finishing process on a consumer product according to one embodiment of the present invention is provided. While the provided flowchart may be comprehensive in some respects, it will be readily understood that not every step provided is necessary, that other steps can be included, and that the order of steps might be rearranged as desired by a given device manufacturer, vendor or user. For example, step  402  may alternatively be performed after steps  404  and/or  406 , since these steps  404  and  406  might be considered to involve the formation of the polishing system itself, after which individual products may then be polished during a manufacturing process. 
         [0048]    After start step  400 , a user can position a component having a complex edge feature, such as consumer product or part thereof, to be held in a fixture at process step  402 . At subsequent process step  404 , a specialized track can be positioned around the fixture that holds the consumer product or part of interest. Again, such a positioning might be accomplished prior to the placement of a part to be polished into the fixture, such as where a large permanently installed track is provided with respect to a given fixture. At a following process step  406 , one or more finishing devices can be disposed on or about the track. Such finishing devices can be, for example, the polishing apparatuses  140  that are described in greater detail above. Again, this step may be accomplished prior to step  402 , if desired. 
         [0049]    The method then continues to process step  408 , where a finishing operation is initiated with respect to the consumer product held in the fixture. At subsequent process step  410 , the finishing device or devices are moved about the track, such as in an orbit of the fixture and product being finished. After one or more movements of finishing devices about the track, the method then proceeds to process step  412 , where the subject finishing operation on the complex edge is finished. In some embodiments, this can result in steps  408  and  410  being performed at the same time, since the finishing procedure can be performed continuously while the one or more finishing devices are orbiting or otherwise rotating about the consumer product. The method then ends at end step  410 . 
         [0050]    Although the foregoing invention has been described in detail by way of illustration and example for purposes of clarity and understanding, it will be recognized that the above described invention may be embodied in numerous other specific variations and embodiments without departing from the spirit or essential characteristics of the invention. Certain changes and modifications may be practiced, and it is understood that the invention is not to be limited by the foregoing details, but rather is to be defined by the scope of the appended claims.