Patent Description:
In recent years, electronic devices, such as notebooks (NB), tablet computers, and smart phones, have been widely used in daily life along with the development of technologies. Types and functions of the electronic devices are increasingly diversified, and the electronic devices are more popular due to convenience and practicality thereof and can be used for different purposes.

In order to maintain a mechanical strength of a casing of an electronic device while pursuing for slim design, a conventional method is to manufacture the casing of the electronic device with different materials by bonding metal parts and plastic parts. The metal parts and the plastic parts may be bonded by adhesives, but such method may lead to steps or gaps generated by differences in element sizes or assembly tolerances between the metal parts and the plastic parts, which affects quality of the casing of the electronic device in terms of exterior. Accordingly, in order to provide the casing of the electronic device with a seamless exterior, it is changed nowadays to bond the metal parts and the plastic part by using an insert molding technique or an in-mold technique. However, an anodizing process may also be adopted as in the conventional art for dyeing the outer surface of the metal parts in current technology, so that the casing of the electronic device may provide a color exterior. During manufacturing processes, if the metal parts of the casing of the electronic device are dyed before bonding the metal parts and the plastic parts, the metal parts are prone to damages from molds in the insert molding process or the in-mold process, which affects the color exterior. If the metal parts and the plastic parts are bonded before dyeing the casing of the electronic device by the anodizing process, an airtight ability between the metal parts and the plastic parts may be insufficient, such that a process solvent used in the anodizing process may easily be remained in between the two, resulting a problem of uneven dyeing in the subsequent dyeing process.

<CIT>discloses antenna structures in electronic devices which may form an antenna having first and second feeds at different locations. Transceiver circuitry for transmitting and receiving radio-frequency antenna signals may be mounted on one end of a printed circuit board. Transmission line structures may be used to convey signals between an opposing end of the printed circuit board and the transceiver circuitry. The printed circuit board may be coupled to an antenna feed structure formed from a flexible printed circuit using solder connections. The flexible printed circuit may have a bend and may be screwed to conductive electronic device housing structures using one or more screws at one or more respective antenna feed terminals. Electrical components such as an amplifier circuit and filter circuitry may be mounted on the flexible printed circuit.

<CIT> discloses custom antenna structures. Such an antenna may have an antenna feed and conductive structures such as portions of a peripheral conductive electronic device housing member. An antenna may be formed from a conductive housing member that surrounds an electronic device. The custom antenna structures may be formed from a printed circuit board with a customizable trace. The customizable trace may have a contact pad portion on the printed circuit board. The customizable trace may be customized to connect the pad to a desired one of a plurality of contacts associated with the conductive housing member to form a customized antenna feed terminal.

The present invention is directed to a metallic housing for an electronic device, as set forth in claim <NUM>. Preferred embodiments of the present invention may be gathered from the dependent claims.

Based on above, in a method of manufacturing the casing of the electronic device of the invention, multiple apertures are formed on the inner surface of the metallic housing, and the non-conductive layer is bonded on the inner surface of the metallic housing, wherein part of the non-conductive layer is extended into the apertures, and part of the non-conductive layer is disposed in the gaps of the metallic housing to form the non-conductive spacers. Accordingly, the electronic device may provide favorable mechanical strength as well as favorable airtight ability between the metallic housing and the non-conductive layer. As a result, the uneven dyeing of the casing of the electronic device may be solved by preventing the process solvent from remaining between the metallic housing and the non-conductive layer, such that the electronic device may provide an even color exterior.

To make the above features and advantages of the invention more comprehensible, several embodiments accompanied with drawings are described in detail as follows.

<FIG> is a schematic diagram of a casing of an electronic device according to an embodiment of the invention. <FIG> is a cross-sectional diagram of the electronic device of <FIG> taken along line I-I'. Referring to <FIG>, in the present embodiment, a casing <NUM> of an electronic device includes a metallic housing <NUM>, a first non-conductive spacer 120a and a second non-conductive spacer 120b, wherein the metallic housing <NUM> includes an inner surface S1 and an outer surface S2 opposite to the inner surface S1. The inner surface S1 is recessed inwardly to substantially form a recessed structure, so that the rest of components (e.g., a battery, a circuit board or an audio device) of an electronic device (not illustrated) may be disposed in the casing <NUM> of the electronic device. The casing <NUM> of the electronic device may be used to cover the rest of components suitable for the electronic device, so as to form the electronic device. The electronic device is, for example, a smart phone, and the casing <NUM> of the electronic device is, for example, a casing of the smart phone. Nonetheless, the types of the electronic device and the casing <NUM> of the electronic device are not particularly limited in the invention.

More specifically, in the present embodiment, the metallic housing <NUM> includes a first gap 112a and a second gap 112b connecting through the inner surface S1 and the outer surface S2. The first gap 112a and the second gap 112b are respectively located at two opposite sides of the metallic housing <NUM> and substantially in parallel, but a relative position of the first gap 112a and the second gap 112b is not particularly limited in the invention. In advance, in the present embodiment, the metallic housing <NUM> includes an upper cover 110a, a middle cover 110b and a lower cover 110c, in which the middle cover 110b is located between the upper cover 110a and the lower cover 110c. The first gap 112a is located between the upper cover 110a and the middle cover 110b, and the second gap 112b is located between the middle cover 110b and the lower cover 110c. In addition, the casing <NUM> of the electronic device of the present embodiment includes a non-conductive layer <NUM> disposed on the inner surface S1 of the metallic housing <NUM>, wherein part of the non-conductive layer <NUM> is exposed to the outer surface S2 of the metallic housing <NUM>. More specifically, part of the non-conductive layer <NUM> of the present embodiment includes a first non-conductive spacer 120a and a second non-conductive spacer 120b which are extended from the inner surface S1 to the outer surface S2. The first non-conductive spacer 120a and the second non-conductive spacer 120b are disposed in the first gap 112a and the second gap 112b of the metallic housing <NUM>, respectively. Furthermore, the non-conductive layer <NUM> also includes a non-conductive frame 120c disposed on the inner surface S1 of the metallic housing <NUM> and surrounding periphery of the metallic housing <NUM> (as illustrated in <FIG>).

In the present embodiment, the first non-conductive spacer 120a and the second non-conductive spacer 120b are substantially strip structure and embedded in the first gap 112a and the second gap 112b. Nevertheless, the shapes of the first non-conductive spacer 120a and the second non-conductive spacer 120b are not particularly limited in the invention. The first gap 112a and the second gap 112b substantially separate the upper cover 110a, the middle cover 110b, and the lower cover 110c from each other. More specifically, in the present embodiment, the first gap 112a and the second gap 112b completely separate the upper cover 110a, the middle cover 110b and the lower cover 110c from each other (as shown in <FIG>), so that the upper cover 110a, the middle cover 110b and the lower cover 110c (which are all conductive) are separated from each other. And, because the first non-conductive spacer 120a and the second non-conductive spacer 120b are non-conductive, the upper cover 110a, the middle cover 110b and the lower cover 110c may be electrically insulated from each other by disposing the first non-conductive spacer 120a and the second conductive spacer 120b in the first gap 112a and the second gap 112b. Accordingly, the metallic housing <NUM> may be divided into a plurality of regions adjacent to but not contacting each other, such as three regions R1, R2 and R3 depicted in <FIG>. However, in other embodiments, the gaps may be selectively disposed at lateral sides of the metallic housing <NUM> based on requirements, and extended only to the middle of the metallic housing <NUM>. In this case, the upper cover 110a, the middle cover 110b and the lower cover 110c may be separated by the gaps, but the upper cover 110a, the middle cover 110b and the lower cover 110c are still contacting each other. In other words, in case the upper cover 110a, the middle cover 110b and the lower cover 110c are not required to be electrically insulated from each other (e.g., in case the upper cover 110a, the middle cover 110b and the lower cover 110c are not used as antenna regions, or different design for the antenna regions are adopted in the subsequent process), the gaps do not need to completely separate the upper cover 110a, the middle cover 110b and the lower cover 110c from each other, thus the invention is not limited to aforesaid embodiment. Although the casing <NUM> of the electronic device of the present embodiment includes the first non-conductive spacer 120a and the second non-conductive spacer 120b and the metallic housing <NUM> includes the first gap 112a and the second gap 112b, the casing <NUM> of the electronic device may still adjust quantity and position of the gaps and non-conductive spacers based on requirement as in other embodiments.

Furthermore, in the present embodiment, the metallic housing <NUM> further includes two connecting terminals <NUM> corresponding to the upper cover 110a and the lower cover 110c of the metallic housing <NUM>, respectively. More specifically, the connecting terminals <NUM> are formed by the inner surface S1 of the metallic housing <NUM>. While disposing the rest of the components of the electronic device in the casing <NUM> of the electronic device, the rest of the components of the electronic device may be electrically connected to the metallic housing <NUM> by the connecting terminals <NUM>. Although the connecting terminals <NUM> of the present embodiment are illustrated as two for example, and the two connecting terminals <NUM> are corresponding to the upper cover 110a and the lower cover 110c, respectively, the casing <NUM> of the electronic device may still adjust quantity and position of the connecting terminals <NUM> of the casing <NUM> of the electronic device based on requirements as in other embodiments.

Since part of the non-conductive layer <NUM> formed in the first gap 112a and the second gap 112b and exposed to the outer surface S2 of the metallic housing <NUM> divides the metallic housing <NUM> into the regions R1, R2 and R3 adjacent to but not contacting each other, wherein the regions R1 and R3 may serve as the antenna region, such that the electronic device may be provided with functions of an antenna. For instance, the antenna region formed by the region R1 may be applied in technologies such as Bluetooth (BT) transmission, Wireless Fidelity (WiFi), Globe Positioning System (GPS) or Diversity antenna; whereas the antenna region formed by the region R3 may be applied in technologies such as global system for mobile communications (GSM), Long Term Evolution (LTE) network and Wide-band Code Division Multiple Access (WCDMA). Therefore, the casing <NUM> of the electronic device allows the electronic device to combine with a plurality of wireless transmission device for expanding functionality of the electronic device.

On the other hand, in the present embodiment, the casing <NUM> of the electronic device has a color appearance which is presented by the outer surface S2 of the metallic housing <NUM> dyed by a process solvent with colors. Therefore, in addition to steps of forming the first gap 112a and the second gap 112b on the metallic housing <NUM>, forming the first non-conductive spacer 120a and the second non-conductive spacer 120b disposed in the first gap 112a and the second gap 112b, and forming the non-conductive frame 120c on the metallic housing <NUM>, process of manufacturing the casing <NUM> of the electronic device according to the embodiments of the invention also requires to dye the metallic housing <NUM>. Accordingly, an order of aforesaid steps may affect a yield rate of the process. For instance, if the metallic housing <NUM> is dyed before bonding the dyed metallic housing <NUM> with the non-conductive layer <NUM>, the metallic housing <NUM> is prone to be damaged from molds during the bonding process to affect the color appearance thereof. If the metallic housing <NUM> is bonded with the non-conductive layer <NUM> before dyeing the metallic housing <NUM>, the process solvent may be easily remained between the metallic housing <NUM> and the non-conductive layer <NUM>, resulting a problem of uneven dyeing in the subsequent dyeing process. Accordingly, the casing <NUM> of the electronic device is manufactured by using the following method, which is capable of reducing incidence of said problem to decrease a possibility of the uneven dyeing of the casing of the electronic device.

<FIG> is a flowchart of a method of manufacturing the casing of the electronic device of <FIG>. <FIG> are schematic diagrams illustrating flows for the method of manufacturing the casing of the electronic device of <FIG>. <FIG> illustrate each step in the method of manufacturing the casing <NUM> of the electronic device according to the embodiments of the invention in sequence. The method of manufacturing the casing <NUM> of the electronic device according to the embodiments of the invention are described sequentially in text below by reference with <FIG> and <FIG> to <FIG>.

First, referring to <FIG>, <FIG>, the metallic housing <NUM> is provided in step S110. In the present embodiment, the step of providing the metallic housing <NUM> includes the following steps. In step S112, a metallic sheet <NUM> is provided, as shown in <FIG>. A material of the metallic sheet <NUM> is aluminum for example, but the material of the metallic sheet <NUM> is not particularly limited in the invention. Next, in step S114, the metallic sheet <NUM> is mechanically treated to form the metallic housing <NUM> in which the metallic housing <NUM> includes the inner surface S1 and the outer surface S2 opposite to the inner surface S1. The step of machining the metallic sheet <NUM> includes, for example, a computer numerical control (CNC) treatment, but the method of machining the metallic sheet <NUM> is not particularly limited in the invention. The inner surface S1 recessed inwardly is formed after machining the metallic sheet <NUM> while the outer surface S2 may maintain a status of not being treated, as shown in <FIG>. In addition, in the present embodiment, the step of machining the metallic sheet <NUM> in step S104 includes forming two gaps (the first gap 112a and the second gap 112b) on the inner surface S1 of the metallic housing <NUM>, and the first gap 112a and the second gap 112b are extended to the outer surface S2. In the present embodiment, the step of forming the two gaps includes machining one surface of the metallic sheet <NUM> (e.g., an upper surface of the metallic sheet <NUM> as shown in <FIG>) to form the inner surface S1 recessed inwardly, and then machining another surface of the metallic sheet <NUM> (e.g., a lower surface of the metallic sheet <NUM> as shown in <FIG>), so as to form the first gap 112a and the second gap 112b connecting through the inner surface S1 inwardly from the outer surface S2 of the metallic sheet <NUM>. The first gap 112a and the second gap 112b are respectively located on two ends (a front end and a back end) of the metallic housing <NUM> to substantially divide the metallic housing <NUM> into three regions. In addition, in the step of machining the metallic sheet <NUM> further includes forming a plurality of supporting structures 113a and 113b on the inner surface S1 of the metallic housing <NUM>. The supporting structures 113a and 113b are, for example, connecting bridges, wherein the supporting structures 113a are disposed on the first gap 112a, and the supporting structures 113b are disposed on the second gap 112b. Although only one of the supporting structures 113a and only one of the supporting structures 113b are illustrated in the cross-sectional diagram of <FIG>, practically, two supporting structures 113a and two supporting structures 113b may be disposed on the inner surface S1 of the metallic housing <NUM> (as illustrated in <FIG>). That is, each of the gaps is correspondingly disposed with two supporting structures. Because the first gap 112a and the second gap 112b of the present embodiment substantially penetrate through the metallic housing <NUM> to divide the metallic housing <NUM> into the three regions not contacting each other, a relative position between the three regions of the metallic housing <NUM> and mechanical strengths thereof may be maintained by disposing the supporting structures 113a and 113b. Despite the present embodiment disposing the two supporting structures between each of the gaps, in other embodiments, each of the gaps may also be disposed with only one or even more of the supporting structures, and the invention is not limited thereto. Further, in an embodiment with the metallic housing <NUM> not completely separated by the gaps, said supporting structures may be omitted, and whether to dispose the supporting structures or not is not particularly limited in the invention. Forming the gaps on the inner surface S1 of the metallic housing allows the non-conductive layer <NUM> formed in the subsequent steps to also extend into the gaps, thus quantity, position and whether to dispose them or not are not limited in the invention, which may be adjusted based on requirements.

Next, referring to <FIG>, <FIG> and <FIG>, a plurality of apertures <NUM> are formed on the inner surface S1 of the metallic housing <NUM> in step S120, and the non-conductive layer <NUM> is formed on the inner surface S1 of the metallic housing <NUM> and part of the non-conductive layer <NUM> is extended into the apertures <NUM> in step S130. In the present embodiment, the step of forming the apertures <NUM> on the inner surface S1 of the metallic housing <NUM> includes a nano molding technology (NMT), but the invention is not limited thereto.

In <FIG>, the step of forming the apertures <NUM> on the inner surface S1 of the metallic housing <NUM> (step S120) includes flushing the inner surface S1 of the metallic housing <NUM> by an acidic solvent, and forming the apertures <NUM> on the inner surface S1 of the metallic housing <NUM>. An inner diameter d of the apertures <NUM> is between <NUM> to <NUM>. In other words, a size of the apertures <NUM> formed on the inner surface S1 of the metallic housing <NUM> is in nanoscale. In addition, because the inner surface S1 of the metallic housing <NUM> of the present embodiment includes the first gap 112a and the second gap 112b, the step of forming the apertures <NUM> on the inner surface S1 of the metallic housing <NUM> (step S120) further includes forming the apertures <NUM> on surfaces of the gaps (the first gap 112a and the second gap 112b) of the metallic housing <NUM>. In other words, the inner surface S1 of the metallic housing <NUM> and the surfaces of the first gap 112a and the second gap 112b may all have the apertures <NUM> formed thereon by the acidic solvent at the same time. For the convenience of the process, the step of flushing the inner surface S1 of the metallic housing <NUM> (step S120) may include flushing the entire metallic housing <NUM> by the acidic solvent (e.g., dipping the entire metallic housing <NUM> into the acidic solvent), or flushing the metallic housing <NUM> comprehensively by the acidic solvent, so as to form the apertures <NUM> on surfaces (including the inner surface S1, the outer surface S2, and the surfaces of the first gap 112a and the second gap 112b) of the entire metallic housing <NUM>. In other words, whether the outer surface S2 of the metallic housing <NUM> includes the apertures <NUM> is not particularly limited in the invention.

In the present embodiment, the method of manufacturing the casing <NUM> of the electronic device further includes the following steps. The metallic housing <NUM> is washed before the step of flushing the entire metallic housing <NUM> by the acidic solvent, and after the step of flushing the entire metallic housing <NUM> by the acidic solvent. More specifically, after the step of providing the metallic housing <NUM> (step S110), and before the step of flushing the entire metallic housing <NUM> by the acidic solvent, the metallic housing <NUM> may be washed to prevent dust or oil remained during the process of machining from affecting the surfaces of the metallic housing <NUM> and reacting with the acidic solvent thereby influencing the formation of the apertures <NUM>. Similarly, after the step of flushing the entire metallic housing <NUM> by the acidic solvent, the metallic housing <NUM> may be washed to prevent the acidic solvent from remaining to affect the subsequent process of dyeing the metallic housing <NUM>.

<FIG> is a schematic diagram of the casing of the electronic device of <FIG> may be considered as a cross-sectional diagram of the casing of the electronic device of <FIG> taken along line A-A'. Referring to <FIG> and <FIG>, in the present embodiment, the step of forming the non-conductive layer <NUM> on the inner surface S1 of the metallic housing <NUM> (step S130) includes an in-mold process, wherein a material of the non-conductive layer <NUM> may be a plastic, but material and forming method of the non-conductive layer <NUM> are not particularly limited in the invention. The step of forming the on-conductive layer <NUM> on the inner surface S1 of the metallic housing <NUM> (step S130) includes, for example, placing the metallic housing <NUM> into a mold (not illustrated), and injecting a flowing plastic into the mold, wherein part of the flowing plastic is filled into the apertures <NUM>, so that part of the non-conductive layer <NUM> after molding may be extended into the apertures <NUM>, as shown in <FIG>. The non-conductive layer <NUM> of the present embodiment is formed periphery on the inner surface S1 of the metallic housing <NUM>. The non-conductive layer <NUM> surrounds periphery of the inner surface S1 in circle, and constitutes a local side of the casing <NUM> of the electronic device after the following-up processes. In addition, because the metallic housing <NUM> of the present embodiment includes the first gap 112a and the second gap 112b, and the apertures <NUM> are provided on the surfaces of the first gap 112a and the second gap 112b, in the step of forming the non-conductive layer <NUM> on the inner surface S1 of the metallic housing <NUM> (step S130), part of the non-conductive layer <NUM> is formed within the gaps (the first gap 112a and the second gap 112b) and extended into the apertures <NUM> formed on the surfaces of the gaps (the first gap 112a and the second gap 112b). In other words, during the in-mold process, part of the flowing plastic may also flow into the first gap 112a and the second gap 112b as well as the apertures <NUM> located on the surfaces of the first gap 112a and the second gap 112b, so that part of the non-conductive layer <NUM> after molding may be extended into the first gap 112a and the second gap 112b as well as the apertures <NUM> located on the surfaces of the first gap 112a and the second gap 112b.

In the method of manufacturing the casing <NUM> of the electronic device, the apertures <NUM> are formed on the inner surface S1 of the metallic housing <NUM> and the surfaces of the first gap 112a and the second gap 112b before the step of forming the non-conductive layer <NUM> on the inner surface S1 of the metallic housing <NUM> and the first gap 112a and the second gap 112b, thus the non-conductive layer <NUM> may be extended into the apertures <NUM>. In the present embodiment, the metallic housing <NUM> and the non-conductive layer <NUM> are bonded by the in-mold process, and part of the non-conductive layer <NUM> is extended into the apertures <NUM>, such that a favorable bonding force may be provided between the metallic housing <NUM> and the non-conductive layer <NUM> for enhancing the mechanical strength of the casing <NUM> of the electronic device formed in the subsequent process. In addition, because the size of the apertures <NUM> of the present embodiment is in nanoscale, the flowing plastic may be completely infiltrated into the apertures <NUM>. Accordingly, a favorable airtight ability may be provided between the metallic housing <NUM> and the non-conductive layer <NUM> to stop liquid or gas from passing through, so as to achieve a zero-gap design.

Next, referring to <FIG>, <FIG> and <FIG>. Therein, <FIG> is a schematic diagram of the casing of the electronic device of <FIG> may be considered as a cross-sectional diagram of the casing of the electronic device of <FIG> taken along line B-B'. In step S140, the outer surface S2 of the metallic housing <NUM> is mechanically treated. In the present embodiment, after the step of forming the non-conductive layer <NUM> on the inner surface S1 of the metallic housing <NUM> (step S130), the outer surface S2 of the metallic housing <NUM> is mechanically treated to remove part of the metallic housing <NUM> to expose part of the non-conductive layer <NUM> formed in the first gap 112a and the second gap 112b to the outer surface S2 of the metallic housing <NUM>, so as to form a plurality of non-conductive spacers (the first non-conductive spacer 120a and the second non-conductive spacer 120b) located in the first gap 112a and the second gap 112b. In addition, lateral sides of the outer surface S2 of the metallic housing <NUM> are also removed, wherein part of the non-conductive layer <NUM> surrounding periphery of the inner surface S1 forms the non-conductive frame 120c, and constitutes sidewalls of the casing <NUM> of the electronic device together with the rest of the lateral sides of the metallic housing <NUM>, as shown in <FIG>. The step of machining the outer surface S2 of the metallic housing <NUM> includes, for example, a computer numerical control (CNC) treatment, but the method of machining the outer surface S2 of the metallic housing <NUM> is not particularly limited in the invention. By machining the outer surface S2 of the metallic housing <NUM>, a shape of the appearance of the casing <NUM> of the electronic device may be adjusted accordingly. For instance, the lateral sides of the metallic housing <NUM> of the present embodiment are substantially aligned with the non-conductive frame 120c, so that the sidewalls of the casing <NUM> of the electronic device may be flat. In addition, by machining the outer surface S2 of the metallic housing <NUM>, the first non-conductive spacer 120a and the second non-conductive spacer 120b may be exposed to the lateral sides of the metallic housing and substantially aligned with the lateral sides of the metallic housing <NUM>. Accordingly, the outer surface S2 of the metallic housing <NUM> and the first non-conductive spacer 120a, the second non-conductive spacer 120b and the non-conductive frame 120c exposed to the outer surface S2 of the metallic housing <NUM> may provide a seamless appearance, but the invention is not limited thereto, they may be adjusted based on requirements in the shape of the casing <NUM> of the electronic device.

Furthermore, in the present embodiment, the first non-conductive spacer 120a and the second non-conducive spacer 120b formed in the first gap 112a and the second gap 112b and exposed to the outer surface S2 of the metallic housing <NUM> may divide the metallic housing <NUM> into the upper cover 110a, the middle cover 110b, and the lower cover 110c which are separated and electrically insulted from each other, and the upper cover 110a, the middle cover 110b, and the lower cover 110c may correspondingly from the three regions which are adjacent to but not contacting each other, such as the regions R1, R2, and R3. The upper cover 110a, the middle cover 110b, and the lower cover 110c which are separated from each other may be connected by the supporting structures 113a and 113b, so as maintain the relative position thereof during the process of manufacturing the casing <NUM> of the electronic device. However, in other embodiments, although the gaps and the non-conductive spacers formed in the gaps and exposed to the outer surface S2 of the metallic housing <NUM> may divide the metallic housing <NUM> into the regions which are adjacent to but not contacting each other, quantity and range of the regions may by adjusted according to quantity and position of the gaps and the non-conductive spacers and whether to dispose them, and the invention is not limited thereto.

Next, referring to <FIG>, in step S150, a surface treatment process is performed to the outer surface S2 of the metallic housing <NUM>. In the present embodiment, after the step of machining the outer surface S2 of the metallic housing <NUM> (step S140), the surface treatment process is performed to the outer surface S2 of the metallic housing <NUM>. The surface treatment process may include cleaning the outer surface S2 of the metallic housing <NUM>, and may also be decorating the outer surface S2 of the metallic housing <NUM>. A method of decorating the outer surface S2 of the metallic housing <NUM> may be, for example, forming a rough surface on the outer surface by a sandblasting process, or making the outer surface S2 a glossy surface by a polishing process, or may also be forming hairlines on the outer surface S2 by a grinding process, so that the outer surface S2 of the metallic housing <NUM> may provide a special tactile effect or a special visual effect. In other embodiments, the type of the surface treatment process may be selected based on actual requirements, and the surface treatment process to the outer surface S2 the metallic housing <NUM> may also be omitted.

Next, referring to <FIG> and <FIG>, in step S160, the outer surface S2 of the metallic housing <NUM> is dyed to from the casing <NUM> of the electronic device. In the present embodiment, the step of dyeing the outer surface S2 of the metallic housing <NUM> includes an anodizing process. The anodizing process is a surface treatment technology with a main purpose to extend lifetime of a metal object or improve an aesthetics of the metal object by changing physical, mechanical, and chemical properties of a surface of the metal object for improving a surface characteristic thereof (e.g., improving capabilities like etch-proof, heat-proof, or improving conductivity for the metal object). In the anodizing process, the metal object (e.g., metallic housing <NUM> of the present embodiment) is placed at a anode in an electrolysis tank, and a determined voltage and current is applied to facilitate the surface of the metal object in forming a favorable metal oxide layer, and the metallic housing <NUM> may provide the same voltage to the upper cover 110a, the middle cover 110b and the lower cover 110c through conduction of the supporting structures 113a and 113b (as shown in an enlarged diagram of <FIG>). Because the material of metallic housing <NUM> in the present embodiment is aluminum, a material of the metal oxide layer formed on the outer surface S2 of the metallic housing <NUM> by the anodizing process is aluminum oxide. Accordingly, the anodizing process is capable forming the metal oxide layer (which is dense and with protectiveness) based on a base metal on the surface of the metallic housing <NUM>, so as to enhance the mechanical strength of the metallic housing <NUM>. And, said metal oxide layer may include apertures, such that the colors in the subsequent dyeing step may be infiltrated into inner layers of the metallic housing <NUM>. After forming the metal oxide layer on the outer surface S2 of the metallic housing <NUM>, the metallic housing <NUM> having the metal oxide layer may be dyed by the process solvent with colors. Dyes in the process solvent may be filled into the apertures of the metal oxide layer to dye the metal oxide layer, so that the casing <NUM> of the electronic device may provide the color appearance. After dyeing by the process solvent with colors, a washing process may performed to the casing <NUM> of the electronic device having the color appearance, so as to decrease the possibility of the uneven dyeing caused by the remained process solvent.

Lastly, referring to <FIG> and <FIG>, in step S170, part of the non-conductive layer <NUM> and part of the metallic housing <NUM> are removed from the inner surface S1 of the metallic housing <NUM>, so that the connecting terminals <NUM> may be formed by part of the inner surface S1 of the metallic housing <NUM>. More specifically, the descriptions and the drawings for forming the non-conductive layer <NUM> in the foregoing embodiments merely illustrates that the non-conductive layer <NUM> includes the first non-conductive spacer 120a, the second non-conductive spacer 120b and the non-conductive frame 120c. But in actual processes, it is also possible that the non-conductive layer <NUM> may be formed on part of the inner surface S1 of the metallic housing <NUM>. For example, a non-conductive material may be remained on the inner surface S1 near the gaps while being filled into the gaps, or the non-conductive material may be remained on the inner surface S1 near four corners of the non-conductive frame 120c while forming the non-conductive frame 120c. Therefore, after the step of dyeing the outer surface S2 of the metallic housing <NUM> (step S160), part of the non-conductive layer <NUM> may be removed from the inner surface S1 of the metallic housing <NUM> based on actual requirements.

Furthermore, referring to <FIG> and <FIG> is a schematic diagram of the casing of the electronic device of <FIG> may be considered as a cross-sectional diagram of <FIG> taken along line C-C'. At the time, the upper cover 110a, the middle cover 110b, and the lower cover 110c to be separated and electrically insulated from each other as mentioned above are practically still connected to each other through the supporting structures 113a and 113b. Therefore, after the step of dyeing the outer surface S2 of the metallic housing <NUM> (step S160), part of the metallic housing <NUM> may be removed from the inner surface S1 of the metallic housing <NUM> based on actual requirements. For instance, <FIG> shows a status in which the two supporting structures 113a and one of the supporting structures 113b in <FIG> are removed. The step of removing part of non-conductive layer <NUM> or part of the metallic housing <NUM> from the inner surface S1 of the metallic housing <NUM> includes, for example, a computer numerical control (CNC) treatment, but the invention is not limited thereto. Because the first non-conductive spacer 120a and the second non-conducive spacer 120b formed in the first gap 112a and the second gap 112b and exposed to the outer surface S2 of the metallic housing <NUM> divides the metallic housing <NUM> into the regions R1, R2, and R3 adjacent to but not contacting each other, after removing the two supporting structures 113a from the inner surface S1 of the metallic housing <NUM>, the upper cover 110a and the middle cover 110b (which are corresponding to the regions R1 and R2, respectively) may be separated and electrically insulated from each other, whereas the middle cover 110b and the lower cover 110c (which are corresponding to the regions R2 and R3, respectively) may still be electrically connected to each other through the supporting structure 113b that is not yet removed. The connecting terminals <NUM> may be formed on the metallic housing <NUM> by part of the inner surface S1 corresponding to the regions R1 and regions R2 or R3. Accordingly, the regions R1 and R3 of the casing <NUM> of the electronic device may be electrically connected to the electronic device through the inner surface S1 to form an antenna, such that the electronic device may be provided with functions of the antenna. Therein, the region R1 may individually serve as one antenna, and the regions R2 and R3 electrically connected to each other through the supporting 113b may serve as another antenna region.

In the present embodiment, the non-conductive layer <NUM> may be selected from a material having favorable mechanical properties and etch-proof characteristic, such as polyphenylene sulfide (PPS), polybutylene terephthalate (PBT), or polyamide (PA), but the invention is not limited by above-said materials. Because the non-conductive layer <NUM> has the favorable mechanical properties, even if part of the non-conductive layer <NUM> are removed from the inner surface S1 of the metallic housing <NUM> by mechanical treatment, the mechanical strength and the bonding force between the metallic housing <NUM> and the non-conductive layer <NUM> cannot be affected, and the airtight ability between the metallic housing <NUM> and the non-conductive layer <NUM> cannot be affected either. In addition, because the non-conductive layer <NUM> has the etch-proof characteristic, even if the outer surface S2 of the metallic housing <NUM> is dyed by the anodizing process after the step of forming the non-conductive layer <NUM> on the inner surface S1 of the metallic housing <NUM>, the non-conductive layer <NUM> cannot be etched by the process solvent used in the anodizing process.

On the other hand, because the favorable airtight ability is provided between the metallic housing <NUM> and the non-conductive layer <NUM>, the process solvent used in the step of dyeing the outer surface S2 of the metallic housing <NUM> by the anodizing process cannot be remained between the metallic housing <NUM> and the non-conductive layer <NUM>. In other words, because the zero-gap design is achieved between the metallic housing <NUM> and the non-conductive layer <NUM>, the process solvent cannot enter spaces between the metallic housing <NUM> and the non-conductive layer <NUM>. Therefore, in the subsequent dyeing process, because the process solvent is not remained between the metallic housing <NUM> and the non-conductive layer <NUM>, the uneven dyeing of the casing <NUM> of the electronic device caused by the process solvent would not happen. In other words, because the apertures <NUM> provide the favorable airtight ability between the metallic housing <NUM> and the non-conductive layer <NUM>, the uneven dyeing of the casing <NUM> of the electronic device caused by the process solvent leaked in the subsequent dyeing process and remained between the metallic housing <NUM> and the non-conductive layer <NUM> may be solved.

In summary, in the method of manufacturing the casing of the electronic device of the invention, multiple apertures are formed on the inner surface of the metallic housing by the nano molding technology, and the non-conductive layer is bonded on the inner surface of the metallic housing by the in-mold process, wherein part of the non-conductive layer is extended into the apertures, and part of the non-conductive layer is disposed in the gaps of the metallic housing to form the non-conductive spacers, so as to divide the metallic housing into multiple regions. Accordingly, the electronic device may provide the favorable mechanical strength as well as the favorable airtight ability between the metallic housing and the non-conductive layer. Moreover, the uneven dyeing of the casing of the electronic device may be avoided by preventing the process solvent from remaining between the metallic housing and the non-conductive layer during the subsequent process of dyeing the metallic housing by the anodizing process, such that the electronic device may provide an even color appearance.

Claim 1:
A metallic housing (<NUM>) of an electronic device, comprising:
an inner surface (S1) and an outer surface (S2) opposite to the inner surface, and also having a back side and at least one lateral side, wherein the inner surface (S1), the outer surface (S2), the back side and the at least one lateral side form at least part of the metallic housing (<NUM>), the inner surface (S1) being substantially a recessed structure, and the metallic housing (<NUM>) having a first gap (112a) communicating the inner surface (S1) and the outer surface (S2) wherein a first plurality of apertures (<NUM>) are formed on a surface of the first gap (112a);
at least one connecting terminal (<NUM>); and
a first non-conductive spacer (120a), disposed in the first gap (112a) of the metallic housing (<NUM>); wherein the first non-conductive spacer (120a) extends from a first side of the at least one lateral sides of the metallic housing (<NUM>) to the back side of the metallic housing (<NUM>) and further extends to a second side of the at least one lateral side opposite to the first side of the metallic housing (<NUM>),
wherein part of the first non-conductive spacer (120a) is extended into the apertures (<NUM>) of said first plurality of apertures (<NUM>).