Patent Description:
The subject matter of this disclosure relates generally to coupling structures for electronic device housings, and more particularly to coupling structures providing watertight joints between components or segments of electronic device housings.

Electronic device housings often include multiple components that are coupled together to form the housing. For example, two or more housing components may be coupled together to form an outer or exterior surface of the housing and to form an interior cavity or volume in which components of the electronic device are housed. The housing may also include joint structures or other intermediate components positioned between the housing components. The joint structures may form part of an exterior surface of the housing along with the housing components. The housing and joint structures may be formed from various materials, such as metal, plastic, or the like.

<CIT> discloses a waterproof structure for a mobile terminal device including exterior resin extending between a first casing and a second casing that face each other and extending over the outer circumferences thereof, wherein a waterproof gasket is formed along the inner circumference of the exterior resin so as to be integral with exterior resin and is further sandwiched and compressed between the first casing and the second casing.

<CIT> discloses an electronic device having an enclosure formed from at least one ceramic cover and a peripheral structure adjacent the periphery of the ceramic cover and which can be secured adjacent to the ceramic cover with an attachment member, wherein the ceramic cover can include a recess to receive the attachment member and the peripheral structure can be molded adjacent the ceramic cover so that a gapless interface can be formed between the peripheral structure and the periphery of the ceramic cover.

<CIT> discloses a coupling frame to provide structural support and electrical functionality includes a plurality of conductive frames spaced from each other and having predetermined gaps, wherein a plurality of conductive sheets are electrically connected to the different places of the inside surface of the conductive frames and an insulating frame fills in the predetermined gaps, and each conductive frame and the insulating frame are annular structures, and the insulating frame extends inwardly to partially cover the plurality of conductive sheets.

<CIT> discloses a cosmetic finish on a component constructed by connecting several elements, wherein a single manufacturing process, such as machining or grinding, can be applied to the connected elements to remove material from some or all of the elements and to form a smooth and continuous surface across interfaces between the individual elements of the component and, in some cases, settings of the material removal process can be adjusted based on the material of the component elements.

The present invention is defined by the features of the independent claims. Preferred embodiments thereof are defined by the sub-features of the dependent claims.

A housing for an electronic device includes a first conductive component defining a first interface surface, a second conductive component defining a second interface surface facing the first interface surface, and a joint structure between the first and second interface surfaces. The joint structure includes a molded element forming a portion of an exterior surface of the housing, and a sealing member abutting the molded element and forming a watertight seal between the first and second conductive components.

A method of manufacturing a housing for an electronic device includes positioning a sealing member in a first portion of a gap between a first component and a second component, thereby forming a watertight seal between the first and second components, introducing a joining material into a second portion of the gap, and curing the joining material to form a molded element defining a portion of an exterior surface of the housing. In some embodiments, the operation of positioning the sealing member in the first portion of the gap occurs after the operation of curing the joining material to form the molded element, and the operation of introducing the joining material into the second portion of the gap includes flowing the joining material into the first and second portions of the gap, curing the joining material to form a hardened joining material, and removing at least part of the hardened joining material from the first portion of the gap, thereby forming the molded element.

A housing for an electronic device includes a first housing component comprising a conductive material and forming a first portion of an exterior surface of the housing, and a second housing component attached to the first housing component via a watertight joint. The second housing component includes a nonconductive structural member coupled to the first housing component and forming a second portion of the exterior surface of the housing, and a conductive coating on at least a portion of the structural member and forming a third portion of the exterior surface of the housing.

A method of manufacturing a housing for an electronic device includes coupling a first housing component to a second housing component to form a housing having an exterior surface defined at least in part by a portion of the first housing component and a portion of the second housing component, and removing a portion of a conductive coating from the first housing component to expose a substantially nonconductive material under the coating.

A method of manufacturing a housing for an electronic device includes removing material from a housing blank comprising a nonconductive component positioned between and bonded to a first and a second conductive component to form at least an exterior surface of the housing and an interior volume adapted to receive components of the electronic device. After the material is removed, the nonconductive component electrically isolates the first conductive component from the second conductive component, and the interface between the nonconductive component and a surface of the first conductive component is watertight.

Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the scope of the described embodiments as defined by the appended claims.

Housings for electronic devices may include multiple different components. For example, a housing may include a first component that forms a back surface of the housing and a second component that forms a front portion (e.g., a support or frame for supporting a display screen). In order to join the first and second components (and/or to provide other functionality), an intermediate or joining structure formed from a polymer or other suitable material may be positioned between the components. For example, a polymer material in a viscous or flowable state may be introduced into a gap between the housing components and then cured to retain the housing components together. Alternatively, a gasket or other structure may be positioned in the gap and glued or otherwise adhered to the housing components. In some cases, a housing component may be a conductive element that is part of an electrical circuit of the device. In such cases, an intermediate or joining structure may electrically isolate the electrically operative housing component from other housing components. For example, a housing component may act as an antenna for a wireless communication circuit of the electronic device, and an intermediate or joining structure may electrically isolate that component from other conductive housing components to facilitate proper antenna function.

Electronic devices, such as handheld and wearable electronic devices, are often subjected to liquids that, if allowed to enter the device housing, could damage sensitive electric components inside the housing. Where housings are formed from multiple different components joined, it may be advantageous to provide joints between the components that are watertight. As used herein, the term "watertight" refers to the ability of a joint, seal, seam, or interface to prevent water or other liquids from passing therethrough under an anticipated or particular set of conditions. For example, a joint, seal, or interface may be considered watertight when it prevents the passage of water at a particular pressure or water depth (e.g., <NUM> mbar) for a particular duration (e.g., <NUM> hour). Other pressure and duration combinations may also be used, such as immersion at <NUM> for <NUM> minutes and/or being subjected to water jets directed to the device. Other measures, classifications, or standards for watertightness or water resistance may also be used, such as the International Organization for Standardization (ISO) <NUM> or <NUM> standards, International Electrotechnical Commission (IEC) IPX1 - IPX9K standards, or water pressure ratings (e.g., the ability to withstand water pressures up to a value ranging from <NUM>-<NUM> ATM). In general, a joint, seal, seam, or interface may be considered watertight if it prevents the passage of water under foreseeable uses or misuses of an electronic device, such as being worn while swimming or showering, being subjected to sweat, rain, or spills, being dropped into standing water, and the like. Where a joint, seal, seam, or interface is described herein as being watertight, it may comply with any one or more of the aforementioned standards, measures, or classifications.

As noted above, housings may include multiple housing components joined to one another by joint structures. The joint structures may provide various functions. For example, the joint structures may mechanically retain the housing components together while also electrically isolating the housing components from one another. Described herein are various housings where joints or seams between the joint structures and the housing components are watertight. For example, in order to form a watertight housing, a joint structure may include multiple elements, such as an outer element that provides structural and/or cosmetic functionality and forms part of an external surface of the housing, as well as an inner element that provides a watertight seal. The inner element may be, for example, a gasket, O-ring, or other elastomeric or deformable material that is compressed between the housing components. As another example, the inner element may be a sealant, adhesive, or other material that is introduced between the housing components and optionally cured to form the watertight seal.

A watertight seal between housing components may also be formed by assembling a housing blank and machining the housing blank to form the housing. For example, the housing blank may include material for the housing components and material for a joint structure bonded together such that, when machined into a housing, the joint structure is properly positioned between housing components. The bonds between the various materials in the housing blank may be watertight, resulting in watertight interfaces between the housing components and joint structures in the final housing. Details of these and other housings, and methods of forming them, are discussed herein.

<FIG> shows an example electronic device <NUM>. The electronic device <NUM> is a smartphone, but this is merely one representative example of an electronic device that may be used in conjunction with the ideas disclosed herein. Other example electronic devices include, without limitation, wearable electronic devices (such as the smartwatch shown in <FIG>), tablet computers, laptop computers, and the like.

The electronic device <NUM> includes a housing <NUM> and a cover <NUM>, such as a glass, plastic, or other substantially transparent material, component, or assembly, attached to the housing <NUM>. The cover <NUM> may cover or otherwise overlie a display and/or a touch sensitive surface (e.g., a touchscreen).

As shown, the housing <NUM> can be a multi-piece housing. For example, the housing <NUM> can be formed from a body portion <NUM> and end portions <NUM>, <NUM> (<FIG>). The device <NUM> also includes internal components, such as processors, memory, circuit boards, batteries, sensors, and the like. Such components, which are not shown, may be disposed within an internal volume defined at least partially by the housing <NUM>.

<FIG> shows an exploded view of the device <NUM>. The housing <NUM> includes a body portion <NUM> and end portions <NUM>, <NUM> (also referred to herein as a top portion <NUM> and a bottom portion <NUM>). The body portion <NUM> and the end portions <NUM>, <NUM> may be formed from any appropriate material, such as aluminum, titanium, amorphous metals, polymer, or the like. Any of the body portion <NUM> and/or the end portions <NUM>, <NUM> may be part of an electrical circuit of the electronic device <NUM>. In such cases, these components may be formed from or include conductive materials, and may be soldered or otherwise electrically coupled to an electrical circuit that is within the internal volume of the housing <NUM>. As used herein, a component formed from a conductive material may be referred to as a conductive component.

The housing <NUM> also includes joint structures <NUM> between the body portion <NUM> and the top and bottom portions <NUM>, <NUM>. Joint structures <NUM>, also referred to as intermediate structures or components, couple and/or retain one component to another component, and may form a watertight seal between the components that it joins or is adjacent to. For example, the joint structures <NUM> couple the end portions <NUM>, <NUM> to the body portion <NUM>, as described herein. The joint structure <NUM> may include multiple portions, segments, elements, layers, or the like. For example, a joint structure <NUM> may include a first element that mechanically retains the housing components together, and a second element that forms a watertight seal between the joint structure <NUM> and adjacent housing components, as described herein.

The joint structures <NUM> may be formed from or include any appropriate material. For example, joint structures <NUM> or portions thereof may be formed from polymers such as nylon, polyether ether ketone, polysulfone, polyphenylsulfone, polyaryletherketone, polyetherimide, polyethersulfone, or any other appropriate material. Moreover, the joint structures <NUM> may be reinforced with reinforcing fibers of glass, carbon, or any other appropriate material. The joint structures <NUM> may also be formed from or include ceramics, such as zirconia, alumina, or any other ceramic material.

Exterior surfaces of the joint structures <NUM> may form a continuous surface with exterior surfaces of other housing components. Alternatively, the exterior surfaces of the joint structures <NUM> may be recessed from or proud of portions of the housing <NUM> that are adjacent the joint structures <NUM>. Further, the exterior surfaces of the joint structures <NUM> may be configured to blend in with other portions of the housing <NUM>. For example, the joint structures <NUM> may be the same color as nearby portions of the housing <NUM>, may have the same surface finish/texture as exterior portions of the housing <NUM>, or the like. As described herein, the exterior surfaces of the joint structures <NUM> and the housing <NUM> may be co-finished. In other words, the joint structures <NUM> and the housing <NUM> may be subjected to the same finishing processes (e.g., grinding, machining, or polishing) to produce a continuous surface extending across the joint structures <NUM> and adjacent portions of the housing <NUM>, as well as to produce a similar surface finish and/or appearance on the joint structures <NUM> and the housing <NUM>.

The body portion <NUM> and/or the end portions <NUM>, <NUM> may be part of an electrical circuit of the device <NUM>. For example, one or both of the end portions <NUM>, <NUM> may be an antenna, or a portion of an antenna, for wireless communication (e.g., cellular, Wi-Fi, Bluetooth, and so on). Where an end portion is an antenna, or is otherwise part of an electrical circuit, it may be necessary or desirable to electrically and/or capacitively that end portion from other portions of the housing <NUM>, such as the body portion <NUM>. Accordingly, the joint structures <NUM> may be formed from or include an electrical insulator to electrically and/or capacitively isolate the housing components from each other while also coupling them together to form a structurally sound and watertight housing <NUM>. In some embodiments, the roles of the housing components may be reversed such that a joint structure <NUM> is configured to act as an antenna or other circuit component. In such cases, the joint structure <NUM> may be formed from or include a conductive material, and the body portion <NUM> and/or the end portions <NUM>, <NUM> of the housing <NUM> may be formed from a nonconductive material, or may otherwise be electrically isolated from the joint structure <NUM>. The electronic device <NUM> may also or instead include antennas positioned within the housing and proximate the joint structures <NUM> (or embedded in the joint structures <NUM>). In such cases, the joint structures <NUM> may be formed from nonconductive materials to facilitate the passage of wireless signals through the housing <NUM> and to (and from) the internal antennas.

<FIG> shows an example electronic device <NUM> having a different housing configuration than the electronic device <NUM>. As shown in <FIG>, the electronic device <NUM> is a smartwatch, but this is merely one example of an electronic device that may use the housings described herein. Other example electronic devices include, without limitation, smartphones, tablet computers, laptop computers, other wearable devices, and the like.

The electronic device <NUM> includes a housing <NUM> and a cover <NUM>, such as a glass, plastic, or other substantially transparent material, component, or assembly, attached to the housing <NUM>. The cover <NUM> may cover a display and/or a touch sensitive surface (e.g., a touchscreen). The device <NUM> also includes a strap or band <NUM> for attaching the device <NUM> to a user (e.g., to a user's wrist).

As shown, the housing <NUM> can be a multi-piece housing. For example, the housing <NUM> can be formed from a lower housing component <NUM> and an upper housing component <NUM>. The device <NUM> also includes internal components, such as processors, memory, circuit boards, batteries, sensors, and the like (not shown), which may be disposed within an internal volume defined at least partially by the housing <NUM>.

<FIG> shows an exploded view of the device <NUM>. The housing <NUM> includes a lower housing component <NUM>, a joint structure <NUM>, an upper housing component <NUM>, and a cover <NUM>. The upper and lower housing components <NUM>, <NUM> may be formed from any appropriate material, such as aluminum, titanium, amorphous metals, polymer, or the like. Either or both of the upper and lower housing components <NUM>, <NUM> may be part of an electrical circuit of the electronic device <NUM> (e.g., they may act as antennas for a wireless communication circuit), and as such may be conductive components that are formed from or include conductive materials. Where a housing component is part of an electrical circuit, the housing component may be soldered or otherwise electrically coupled to the electrical circuit. Similar to the discussion above, the joint structure <NUM> may be electrically operative instead of the housing components, in which case the joint structure <NUM> may be formed from or include a conductive material, and the housing components <NUM>, <NUM> may be formed from or include a nonconductive material (or they may otherwise be electrically isolated from the joint structure <NUM>). Also, as noted above, a nonconductive joint structure <NUM> may facilitate the passage of wireless signals through the housing <NUM> to reach antennas that are positioned within the housing <NUM> or embedded in the joint structure <NUM>.

Returning to <FIG>, the housing <NUM> includes a joint structure <NUM> between the upper and lower housing components <NUM>, <NUM>. Similar to the joint structures <NUM> described above, the joint structure <NUM> couples and/or retains the upper housing component <NUM> to the lower housing component <NUM>. The joint structure <NUM> is one example joint structure that may be used in the electronic device <NUM>. More particularly, the joint structure <NUM> is a substantially frame-like component that joins the upper and lower housing components <NUM>, <NUM> along a plane that is substantially coplanar with the cover <NUM>. However, other embodiments or implementations of the housing <NUM> may have different configurations and geometries of housing components and joint structures, such as housing components that are separated from one another along joints that are substantially perpendicular to the cover <NUM>. For example, the housing <NUM> (<FIG>) includes joint structures with segments that are substantially perpendicular to the cover <NUM>. A similar structure may be employed in the housing <NUM>. <FIG> illustrates another housing with an alternative joint structure. Indeed, joint structures as described herein may be used between any housing components or portions, not merely those specific examples that are depicted in the figures.

The joint structures <NUM> (<FIG>) and the joint structure <NUM> (<FIG>), as well as the components or portions of the housings <NUM> and <NUM> may be similar in materials, function, construction, methods of manufacturing, etc. Accordingly, any discussion of a joint structure or housing component for a given electronic device applies equally to the joint structures or housing components of other electronic devices. Moreover, while <FIG> illustrate example joint structures for the electronic device <NUM>, the same geometries, materials, electrical characteristics, functions, and manufacturing methods may be applied to the joint structures of the electronic device <NUM> or of any appropriate electronic device.

<FIG> is a partial cross-sectional view of the electronic device <NUM> viewed along line A-A of <FIG>, illustrating one example configuration of a joint structure that may provide a watertight seal between housing components. Other components of the device <NUM>, such as the cover <NUM>, a battery, a display, etc. are omitted from <FIG> (as well as other figures) for clarity.

<FIG> shows a joint structure <NUM> that includes a molded element <NUM> and a sealing member <NUM>. The molded element <NUM> and the sealing member <NUM> are positioned between an interface surface <NUM> of the upper housing component <NUM> and an interface surface <NUM> of the lower housing component <NUM>. The interface surfaces <NUM>, <NUM> face one another, and may be substantially parallel.

The upper housing component <NUM> and/or the lower housing component <NUM> may be formed from or include a conductive material, and may be part of an electrical circuit of the electronic device <NUM>. In such cases, the joint structure <NUM>, including the molded element <NUM> and the sealing member <NUM>, may be formed from an electrical insulator or nonconductive material such that the sealing member <NUM> and the molded element <NUM> electrically isolate the lower housing component <NUM> from the upper housing component <NUM>.

The upper and lower housing components <NUM>, <NUM> may include interlock features <NUM> with which the molded element <NUM> engage to retain the upper and lower housing components <NUM>, <NUM> to the molded element <NUM>, and thus to each other. As shown in <FIG>, the interlock features <NUM> are trapezoidal channels (similar to "dovetail" channels) with angled surfaces that prevent the housing components <NUM>, <NUM> and the molded element <NUM> from separating from one another. Other interlock features may be used instead of or in addition to the trapezoidal channels shown in <FIG>. For example, the housing components may include channels, pins, protrusions, surfaces, textures, recesses, or any other feature or element that engages the molded element <NUM> to retain the housing components <NUM>, <NUM> together.

The interlock features <NUM> may extend continuously around a perimeter of the housing <NUM>. Alternatively, the housing <NUM> may include a plurality of discrete interlock features that do not extend around the entire housing <NUM>. The housing <NUM> may also include different interlock features (or an absence of interlock features) at various positions, such as trapezoidal channels along one side of the housing <NUM> (as shown in <FIG>) and pins along another side of the housing <NUM> (e.g., a side of the housing <NUM> opposite the side shown in <FIG>). The interface surfaces <NUM>, <NUM> may have different interlock features <NUM> as well. For example, the interface surface <NUM> may include trapezoidal channels (as shown in <FIG>), and the interface surface <NUM> may include different interlock features, such as pins, a trapezoidal protrusion, or the like. Moreover, the housing <NUM> may include multiple interlock features <NUM> along a given molded element/housing component interface. For example, two trapezoidal channels may be formed in one or both of the interface surfaces <NUM>, <NUM>.

In some cases, the interlock features <NUM> may be omitted. For example, the molded element <NUM> may be fixed to the housing components <NUM>, <NUM> via an adhesive or an adhesive-like bond, such as where the molded element <NUM> is a polymer that includes an adhesive or otherwise forms a bond with the housing components <NUM>, <NUM> despite the absence of macro-scale interlock features. A separate adhesive may also or instead be applied to the housing components <NUM>, <NUM> and/or the molded element <NUM> to retain the molded element <NUM> to the housing components <NUM>, <NUM>.

The molded element <NUM> may form a portion of an exterior surface of the housing <NUM>. In some cases, the molded element <NUM> may form a continuous or substantially continuous surface with adjacent portions of the upper and lower housing components <NUM>, <NUM>. That is, the seams between the upper and lower housing components <NUM>, <NUM> and the molded element <NUM> may lack a visibly or tactilely perceptible gap, and may generally define a continuous geometric shape (e.g., without drastic or abrupt cavities, channels, seams, gaps, or the like, at the seams).

As noted above, the molded element <NUM> may be co-finished with adjacent portions of the upper and lower housing components <NUM>, <NUM>, which may include grinding, polishing, machining, or other operations. In some cases, the molded element <NUM> may be formed so that the outer surface is recessed relative to the exterior surfaces of the housing components, and material may be removed from the housing components to form a flush and/or continuous surface across the housing components and the molded element <NUM>. In such cases, tools used for finishing the housing components may not contact (or may only incidentally contact) the molded element, thus reducing the possibility of damage to the molded element <NUM> from the tools. A further buffing, polishing, or other finishing operation that is less likely to cause damage to the molded element <NUM> may still be applied to the molded element <NUM> and/or the housing components <NUM>, <NUM> after material is removed from the housing components.

In some embodiments, the molded element <NUM> may not form a watertight seal between the upper and lower housing components <NUM>, <NUM>. For example, the molded element <NUM> may be formed by introducing (e.g., injecting) a flowable polymer material into a gap between the upper and lower housing components <NUM>, <NUM>. When the polymer is cured, it may contract, effectively pulling the molded element <NUM> out of intimate contact with the housing components <NUM>, <NUM> in at least some interfacing portions. These areas may allow water, liquid, or other contaminates to enter the housing <NUM> and potentially damage internal components of the electronic device <NUM>. Where the molded element <NUM> does not reliably produce watertight seals, or to provide a secondary or backup seal, the housing <NUM> may include a sealing member <NUM> positioned on an interior side of the molded element <NUM>. The sealing member <NUM> may be configured to intimately contact the interface surfaces <NUM>, <NUM> of the housing components to form a watertight seal between the upper and lower housing components <NUM>, <NUM>. Moreover, as discussed herein, the molded element <NUM> and the sealing member <NUM> may abut one another, which may eliminate or reduce the occurrence of voids or gaps in the joint structure <NUM> and/or between the joint structure <NUM> and the housing components <NUM>, <NUM>.

The sealing member <NUM> may be formed from or include an elastomeric material that provides suitable sealing properties, such as a rubber, silicone, or the like. The sealing member <NUM> may resemble a gasket or an O-ring that substantially surrounds the housing <NUM> and seals the upper and lower housing components <NUM>, <NUM>.

In some cases, the sealing member <NUM> is compressed between the housing components <NUM>, <NUM> in order to maintain intimate contact between the sealing member <NUM> and the housing components <NUM>, <NUM>. That is, a distance between the housing components <NUM>, <NUM> may be smaller than a thickness of the sealing member <NUM> in an uncompressed or "resting" state. Once compressed between the housing components, the sealing member <NUM> will attempt to expand to its uncompressed or resting thickness, thereby forcing itself against the interface surfaces <NUM>, <NUM>. This interaction may form or contribute to a watertight seal.

By forming the joint structure <NUM> from multiple components (e.g., the molded element <NUM> and the sealing member <NUM>), the functions of the joint structure <NUM> may be shared among different components. This may allow for fewer design compromises for the joint structure <NUM>. For example, a joint structure <NUM> may be desired to securely retain the housing components together, electrically isolate the housing components, form a watertight seal, form a suitably hard and durable surface, withstand chemical and mechanical finishing processes to which the exterior surface of the housing is subjected (e.g., grinding, polishing, anodizing), and satisfy aesthetic or cosmetic requirements (e.g., be capable of being dyed to desired colors or have an attractive visual appearance). In some cases, these design considerations may compete, such that improving the performance in one aspect (e.g., sealing) may reduce the performance in another (e.g., hardness and durability). By providing a separate sealing element, it may be possible to provide a joint structure <NUM> that is better in several respects than one formed of only a single material or structural element. For example, the molded element <NUM> may be formed from or include a material that is hard, durable, and securely retains the housing components together, while the sealing member <NUM> may be formed from a softer material that forms a watertight seal but which may be too soft to be used as an exterior surface of the housing <NUM>.

In some cases, the molded element <NUM> may form a watertight seal with the adjacent surfaces of the housing components <NUM>, <NUM>. In such cases, the sealing member <NUM> may be omitted, or may be used as a secondary sealing member. Molded elements that form a watertight seal may be formed from or include ceramics, epoxies, cermets, or composites (including combinations of polymers, ceramics, epoxies, adhesives, and the like).

<FIG> are partial cross-sectional views of the housing <NUM> viewed along A-A in <FIG>, showing an example process of forming the joint structure <NUM> described above. In <FIG>, the sealing member <NUM> is positioned in a gap <NUM> between the upper and lower housing components <NUM>, <NUM>. As shown, the sealing member <NUM> is placed on the interface surface <NUM> of the lower housing component <NUM>. In some cases, the sealing member <NUM> may be placed on the upper housing component <NUM>, or part of the sealing member <NUM> may be placed on each of the housing components. The sealing member <NUM> is shown having a round cross-section, though a sealing member of any shape or size may be used.

The sealing member <NUM> may be any appropriate structure, component, or material. For example, the sealing member <NUM> may be a pre-formed gasket, O-ring, or other component that is positioned between (or a portion of which is positioned between) the housing components <NUM>, <NUM>. As another example, the sealing member <NUM> may be formed by flowing or otherwise depositing a deformable material on one of the housing components <NUM>, <NUM>. The deposited deformable material may be cured to form a resilient or deformable structure, or may be suitable for sealing without curing. Suitable deformable materials for the sealing member may include foams, rubbers, silicone, wax, polyurethane, neoprene, and so on.

After the sealing member <NUM> or deformable material is positioned in the gap <NUM> (or after the sealing member <NUM> or deformable material is otherwise placed in a suitable position, such as on an interface surface of a housing component), a force <NUM>, represented in <FIG> by arrows, may be applied to one or both of the housing components <NUM>, <NUM>. The force compresses the sealing member <NUM> or deformable material in a first portion of the gap <NUM> that is proximate an internal volume of the housing <NUM>, thereby forming a seal between the surfaces of the sealing member <NUM> and the interface surfaces <NUM>, <NUM> of the housing components <NUM>, <NUM>. The seal formed by the sealing member <NUM> or deformable material may be a watertight seal, as described above. As shown in <FIG>, the sealing member <NUM> or deformable material changes shape in response to being compressed, though the particular shapes and changes in size, shape, and aspect ratio shown in the figures are for representation and may not correspond to an actual implementation.

The force <NUM> may be produced by placing the upper and lower housing components <NUM>, <NUM> in a jig, mold, clamp, or other fixture after the sealing member <NUM> is properly positioned. The fixture may hold the housing components <NUM>, <NUM> in a spaced apart orientation such that the gap <NUM> is formed and the sealing member <NUM> is compressed between the housing components. A shim, spacer, or other component (not shown) may also be positioned in the gap <NUM> or otherwise between the upper and lower housing components <NUM>, <NUM> to establish and maintain the gap size during further processing. For example, the shim, spacer, or other component may be positioned in the gap <NUM> before the sealing member <NUM> is compressed in the gap <NUM>, and may cooperate with a jig, mold, clamp, or other fixture to define and maintain the size of the gap <NUM>. The shim may be any appropriate size or shape, such as a continuous shim that extends along the entire gap (though not necessarily filling the entire gap), or a smaller shim that extends along only a part of the gap. Moreover, multiple shims may be used, such as one shim for each linear portion of the housing <NUM>, or one shim for each corner of the housing <NUM>, or, in the case of a circular housing, three shims spaced <NUM> degrees apart around the housing. Other shims and shim arrangements are also contemplated.

The jig, mold, clamp, or other fixture may also define mold surfaces that substantially cover and/or enclose the external opening of the gap <NUM> and define a shape of an exterior surface of the molded element <NUM>. Accordingly, the joining material may flow against the mold surfaces when it is introduced into the gap <NUM>, thereby forming a molded element <NUM> with an exterior surface corresponding to the mold surfaces. More particularly, the mold surfaces may define a contour or shape that will result in the molded element <NUM> having an exterior surface that is continuous with adjacent portions of the housing.

After the sealing member <NUM> is compressed, a joining material may be injected, flowed, or otherwise introduced into a second portion of the gap <NUM> that is proximate an exterior surface of the housing or generally outboard from the sealing member <NUM> to form the molded element <NUM> (as represented by arrow <NUM>, <FIG>). The joining material may flow into, around, and/or against the interlock features <NUM> to form complementary shapes and/or structures in the material, as shown in <FIG>. Similarly, the joining material may flow against and abut the sealing member <NUM>, forming a shape that is complementary to the sealing member <NUM>. The joining material may adhere to or otherwise bond to the sealing member <NUM>. The intimate contact between the joining material and the sealing member <NUM> may reduce or eliminate voids in the joint structure <NUM> (and in particular between the molded element <NUM> and the sealing member <NUM>), thereby producing a more secure or watertight seal between the housing components <NUM>, <NUM>. Indeed, such voids or gaps may cause liquids to be drawn into the voids via capillary action, which may increase the likelihood of liquid ingress into the housing <NUM> or other damage to the housing <NUM> and/or the joint structure <NUM>.

The joining material may also flow against mold surfaces to define an exterior surface of the molded element <NUM>, which is also an exterior surface of the housing <NUM>. The joining material is then cured, thereby solidifying or hardening the joining material and forming the molded element <NUM>. Where a shim or spacer is used to maintain the size of the gap <NUM>, it may be removed after the joining material is cured, as the cured material retains the housing components together and maintains the size of the gap <NUM>.

Because the joining material is introduced into the gap <NUM> and cured while the sealing member <NUM> is compressed between the housing components, the sealing member <NUM> may remain in a compressed state after the force is removed. That is, once the joining material is introduced into the gap and cured to form the molded element <NUM>, the size of the gap <NUM> is maintained such that a residual compressive force is maintained on the sealing member <NUM>, thus providing a positive contact between the sealing member <NUM> and the housing components.

After the molded element <NUM> is at least partially cured, the housing <NUM> may be subjected to further finishing or processing steps. For example, the housing <NUM> may be anodized, chemically treated, plated, washed, or the like. As another example, the housing <NUM> may be subjected to machining, grinding, or polishing. Such finishing and processing steps may be applied to the housing components <NUM>, <NUM> (which may be metal), as well as the molded element <NUM> (which may be a polymer). In particular, a grinding, machining, or polishing step may include traversing the exterior surface of the housing <NUM> with an appropriate tool, including traversing along the upper housing component <NUM>, the molded element <NUM>, and the lower housing component <NUM> in a continuous path. Accordingly, the molded element <NUM> may be formed from a material that can be subjected to the same finishing or processing steps as the housing components. For example, if the housing components <NUM>, <NUM> are to be ground and polished in order to achieve a desired surface finish, the molded element <NUM> may be formed from a material that, when subjected to the same grinding and polishing operations as the housing components <NUM>, <NUM>, produces a desirable surface finish (e.g., it does not chip, crack, or melt, and produces a smooth or otherwise desirable surface).

<FIG> are partial cross-sectional views of the housing <NUM> viewed along line A-A in <FIG>, showing another example process of forming the joint structure <NUM> described above. The process illustrated in <FIG> is similar to that described with respect to the process illustrated in <FIG>, but illustrates a process where the upper and lower housing components <NUM>, <NUM> are fixed to one another by a joining member to define and/or substantially maintain the size of the gap until the molded element <NUM> (and/or the sealing member <NUM>) is formed and cured.

<FIG> shows the upper housing component <NUM> fixed to the lower housing component <NUM> via a joining member <NUM>. As shown, the joining member <NUM> and the upper and lower housing components <NUM>, <NUM> are a single monolithic component. In other embodiments (not shown), the joining member may be a separate piece of material that is bonded or otherwise attached to the upper and lower housing potions <NUM>, <NUM>. The joining member <NUM> may extend continuously around an entire inner perimeter of the internal volume of the housing <NUM> (e.g., completely enclosing the inner opening of the gap <NUM>). Alternatively, the joining member <NUM> may be a segment of material that does not extend around the entire housing <NUM>. In some cases, multiple joining members <NUM> may be distributed at various locations around the perimeter of the interior volume of the housing <NUM>.

While the joining member <NUM> is maintaining the size of the gap, the sealing member <NUM> may be introduced or pressed into the gap <NUM>, as shown in <FIG>. For clarity, only a portion of the sealing member <NUM> is shown in <FIG>. For example, the sealing member <NUM> may be an O-ring or otherwise form a continuous loop, and segments of the loop that would be visible in the background in <FIG> are omitted for clarity. In some cases, however, the sealing member <NUM> may not form a continuous loop. For example, multiple discrete sealing members <NUM> may be positioned along the interface between the upper and lower housing components <NUM>, <NUM>.

In its relaxed or uncompressed state, the sealing member <NUM> (or other deformable material) may be taller than the gap <NUM>. Accordingly, when pressed or forced into the gap <NUM>, the sealing member <NUM> is compressed between the upper and lower housing components <NUM>, <NUM>, thereby forming a watertight seal between the sealing member <NUM> and the interface surfaces <NUM>, <NUM> of the housing components <NUM>, <NUM>. As noted above, the sealing member <NUM> may be an O-ring, gasket, or other piece of material (e.g., deformable material) that can be fit into the gap <NUM>. Where the gap <NUM> extends around a perimeter of the housing <NUM>, the sealing member <NUM> may be a continuous elastomeric gasket that is stretched to fit around the outer edge, and then returns to a resting size to draw itself into the gap <NUM>.

Instead of compressing a larger sealing member <NUM> into a smaller gap <NUM>, the sealing member <NUM> may be formed from or include an expanding material, such as a polymer material that can be introduced into the gap <NUM> and then expanded to form a watertight seal with the interface surfaces <NUM>, <NUM>. For example, a propellant such as pressurized gas or a chemical that decomposes to form a gas may be mixed with or otherwise incorporated in an expandable polymer material. Once the material is introduced in the gap <NUM>, the propellant may cause the material to expand and force the material against the interface surfaces <NUM>, <NUM>.

After the sealing member <NUM> is introduced into the gap <NUM>, the housing <NUM> may be introduced into a mold or other apparatus having mold surfaces that cover the opening of the gap <NUM>. Material (e.g., a joining material) is then flowed, injected, or otherwise introduced into the gap <NUM> (as represented by arrow <NUM>, <FIG>). The joining material may flow into, around, and/or against the interlock features <NUM> to form complementary structures in the material, and may also flow against the mold surfaces to define an exterior surface of the molded element <NUM>. Other aspects of the molded element <NUM> as well as the process of forming the molded element <NUM> are described above, and apply equally to the process described with respect to <FIG>. For example, the molded element <NUM> may contact and/or abut the sealing member <NUM> and form a complementary surface against the sealing member <NUM>.

After the material forming the molded element <NUM> is cured and the molded element <NUM> has retained the upper and lower housing components <NUM>, <NUM> together, the joining member <NUM> may be removed. For example, a machining or cutting operation (e.g., laser, plasma, or water jet cutting) may cut along the line <NUM> in <FIG> to remove the joining member <NUM>. Because the sealing member <NUM> and the molded element <NUM> are electrical insulators, removing the joining member <NUM> electrically decouples the upper and lower housing components <NUM>, <NUM>. <FIG> illustrates the housing <NUM> after the joining member <NUM> is removed.

In some cases, it may be useful to electrically couple one housing component to another housing component. For example, an antenna design may call for the housing components to be physically separated from one another at certain locations (optionally with the joint structure <NUM> therebetween), and electrically coupled at other locations. In housings where the housing components are to be electrically coupled at certain locations, the joining member <NUM> (or other joining members) may not be removed, thus providing the desired electrical connection between the housing components.

<FIG> shows a joint structure <NUM> that includes a first molded element <NUM> and a sealing member <NUM> that is a second molded element. The joint structure <NUM> may be an alternative to the joint structure <NUM>, but may otherwise perform the same or similar functions as the joint structure <NUM>, including mechanically retaining housing components together, electrically isolating the housing components, and forming a watertight seal between the housing components.

The first molded element <NUM> is similar to the molded element <NUM> described above. For example, the first molded element <NUM> may be formed from the same materials and using the same techniques (e.g., injecting or flowing a polymer material into the gap <NUM> and against mold surfaces that define the exterior edge of the molded element <NUM>). The first molded element <NUM> may also have the same or similar structure and perform the same or similar functions as the molded element <NUM>. For example, the first molded element <NUM> may engage interlock features of the upper and lower housing components <NUM>, <NUM>.

The second molded element <NUM> may perform the same or similar functions as the sealing member <NUM>. For example, the second molded element <NUM> may form a watertight seal between the upper and lower housing components <NUM>, <NUM>. Instead of compressing a preformed sealing member or material (e.g., to deform the material and rely on the residual force of the sealing member to form the watertight seal), the second molded element <NUM> may be molded in-place in a manner similar to the molded element <NUM>.

<FIG> are partial cross-sectional views of the housing <NUM> viewed along line A-A in <FIG>, showing an example process of forming the joint structure <NUM> described above. Aspects of the process illustrated in <FIG> may be similar to or the same as the process illustrated in <FIG> and <FIG>. For clarity, those details may be omitted from the discussion of <FIG>, but it will be understood that they apply equally to this process.

In <FIG>, a spacer <NUM> is positioned between the upper and lower housing components <NUM>, <NUM> to support the housing components in a spaced-apart configuration. For example, the spacer <NUM> may be positioned in a portion of the gap <NUM> that is proximate an internal volume of the housing <NUM>. The spacer <NUM> may thus support the housing components to define the size of the gap <NUM> and also occupy a portion of the gap <NUM> that will later be filled with the second molded element <NUM>.

After the spacer <NUM> is positioned in the gap <NUM>, the first molded element <NUM> is formed in the portion of the gap <NUM> that is proximate the exterior surface of the housing <NUM>. For example, a first material (e.g., a joining material) may be flowed, injected, or otherwise introduced into the gap <NUM> (as represented by arrow <NUM>, <FIG>). The first material may flow into, around, and/or against the interlock features <NUM> to form complementary shapes and/or structures in the first material, and may also flow against the mold surfaces to define an exterior surface of the first molded element <NUM>. Aspects of the molded element <NUM> as well as the process of forming the molded element <NUM> are described above with respect to the molded element <NUM> and apply equally to the first molded element <NUM> and to the process of forming the first molded element <NUM>.

After the first molded element <NUM> is at least partially cured, the spacer <NUM> may be removed from the gap <NUM> to expose the portion of the gap <NUM> that is proximate the internal volume of the housing <NUM> (e.g., an interior portion of the gap <NUM>). A second material is then flowed, injected, or otherwise introduced into the interior portion of the gap (as represented by arrow <NUM>, <FIG>) and subsequently cured, thereby forming the second molded element <NUM>. The second material flows against and is bounded on one side by an inner surface of the first molded element <NUM>. Once cured, the second material may form a watertight seal between the upper and lower housing components <NUM>, <NUM>.

Like the molded element <NUM> and the sealing member <NUM> shown in <FIG>, the first and second molded elements <NUM>, <NUM> may abut one another in the gap <NUM>. In particular, when the second material is introduced into the interior portion of the gap (<FIG>), the material flows against and conforms to the surface of the first molded element <NUM>. Thus, the second molded element <NUM> forms a complementary surface that abuts the first molded element <NUM>, reducing or eliminating voids, cavities, or gaps in the joint structure <NUM>.

The first and second molded elements <NUM>, <NUM> may be designed to provide different functions to the housing <NUM>, and thus may be formed from different materials. For example, the first molded element <NUM> may be configured to rigidly retain the upper and lower housing components <NUM>, <NUM> together while being sufficiently hard and durable to act as an exterior surface of the device. On the other hand, the second molded element <NUM> may be configured to form a watertight seal between the housing components, and its structural rigidity and impact toughness may be less critical. In some cases, the first material does not substantially bond to the interface surfaces of the housing components <NUM>, <NUM>, and thus may permit liquid or other contaminants to pass between the first molded element <NUM> and the interface surfaces. In such cases, the second molded element <NUM> (e.g., the sealing member) may be formed from an epoxy, glue, adhesive, or other material that does form a watertight bond with the interface surfaces.

<FIG> are partial cross-sectional views of the housing <NUM> viewed along line A-A in <FIG>, showing another example process of forming the joint structure <NUM> described above. Whereas the process shown in <FIG> uses the spacer <NUM> to occupy the portion of the gap <NUM> that is ultimately occupied by the sealing member <NUM>, the process shown in <FIG> includes filling that portion of the gap <NUM> with material of the first molded element <NUM>, and then removing some of the material to form a space for the sealing member <NUM>.

For example, as shown in <FIG>, the upper and lower housing components <NUM>, <NUM> may be positioned relative to each other to define the gap <NUM>. This may include placing the housing components <NUM>, <NUM> in a mold, jig, or other fixture, as described above. Alternatively or additionally, the upper and lower housing components <NUM>, <NUM> may be joined by a joining member, such as the joining member <NUM> (<FIG>). The first material (e.g., a joining material) may then be flowed, injected, or otherwise introduced into the gap <NUM> (as represented by arrow <NUM>), which may include flowing the first material against interlock features <NUM>, as described above. The first material may substantially fill the gap <NUM>, or may otherwise occupy more of the gap <NUM> than is necessary or desirable for the final dimension of the first molded element <NUM>. The first material is then cured or hardened.

Once the first material is at least partially cured or hardened, at least part of the hardened material is removed from the interior portion of the gap <NUM>, thereby forming a final interior dimension and/or shape of the first molded element <NUM>. The first material may be removed by any appropriate process. For example, as shown in <FIG>, a cutting or grinding tool <NUM> may be used to remove a portion of the first material that is proximate the internal volume of the housing <NUM>, thus forming space in the gap <NUM> for the second molded element <NUM> or other sealing member to be positioned or formed. Other techniques, including chemical etching, laser cutting, water cutting, or the like may be used instead of or in addition to grinding or machining.

After the first material is removed from the interior portion of the gap <NUM>, a second material (e.g., a sealing material) is flowed, injected, or otherwise introduced into the now vacant interior portion of the gap (as represented by arrow <NUM>, <FIG>) and subsequently cured. The second material flows against and is bounded on one side by an inner surface of the first molded element <NUM>. Once cured, the second material may form a watertight seal between the upper and lower housing components <NUM>, <NUM>.

While not shown in <FIG>, the housing components <NUM>, <NUM> may include additional interlock features that engage the second molded element <NUM>. Such interlock features may be the same or similar to the interlock features <NUM>, described above. Moreover, such interlock features may be shaped or otherwise configured to help prevent the ingress of water or other liquids into the internal volume of the housing <NUM>. For example, the interlock features may include flutes, ridges, splines, saw-tooth channels, or the like.

<FIG> is a partial cross-sectional view of a housing <NUM> that may be used in the electronic device <NUM> or <NUM>. The housing <NUM> may be similar to the housing <NUM> described above, and may provide similar functionality. For example, one or more of the components of the housing <NUM> may be part of an electrical circuit of an electronic device. More particularly, one or more of the components of the housing <NUM> may be an antenna or form part of an antenna for a wireless communication circuit. The cross-sectional view in <FIG> may correspond to a view of the housing <NUM> along a line similar to line A-A in <FIG>.

The housing <NUM> includes an upper housing component <NUM> and a lower housing component <NUM>. The lower housing component <NUM> may be substantially the same as the lower housing component <NUM> (shown in <FIG>). The upper housing component <NUM> may have an external appearance that is the same or similar to the upper housing component <NUM> and the joint structure <NUM> (<FIG>), but may have a different mechanical structure. In particular, instead of a separate housing component and joint structure, as described in the foregoing examples, the upper housing component <NUM> includes a structural member <NUM> and a coating <NUM> on at least a portion of the structural member <NUM>. The structural member <NUM> may be a polymer or other nonconductive material, and the coating <NUM> may be a metallic or conductive material.

The upper housing component <NUM> may be configured to support a cover, such as the cover <NUM> (<FIG>), and form a watertight seal between the upper housing component <NUM> and the cover <NUM>. For example, the upper housing component <NUM> may define a surface <NUM> on which the cover <NUM> (or another component) is supported. The surface <NUM> may be part of the coating <NUM> (as shown in <FIG>), or it may be part of the structural member <NUM>. For example, the portion of the coating <NUM> defining the surface <NUM> in <FIG> may be omitted, and the structural member <NUM> may be exposed instead.

When a cover is coupled to the surface <NUM>, a watertight seal may be formed between the cover and the surface <NUM>. For example, a gasket, adhesive, or other sealing material may attach the cover to the surface <NUM> and seal the interface between the cover and the surface <NUM>.

As shown in <FIG>, a portion of the structural member <NUM> forms a portion of the exterior surface of the housing <NUM>, as does the coating <NUM>. In some cases, a portion of each of the coating <NUM>, the structural member <NUM>, and the lower housing component <NUM> form a substantially continuous surface. For example, the seams between the structural member <NUM> and the coating <NUM>, and between the structural member <NUM> and the lower housing component <NUM> may lack gaps, grooves, or other surface discontinuities or irregularities, such that the exterior surface of the housing <NUM> is a continuous and/or smooth surface.

In some cases, both the lower housing component <NUM> and the coating <NUM> may be formed from or include a conductive material, such as metal, aluminum, stainless steel, or the like. The structural member <NUM> may be formed from a nonconductive material, such as a polymer, ceramic, or the like. The nonconductive material of the structural member <NUM> electrically isolates the conductive coating <NUM> from the conductive lower housing component <NUM>. This may allow the coating <NUM> and/or the lower housing component <NUM> to be used in electrical circuits of an electronic device, as described above. For example, by electrically isolating the conductive coating <NUM> from the conductive lower housing component <NUM>, the conductive coating <NUM> may be able to function as an antenna for a wireless communications or radio circuit. Also, because the coating <NUM> is electrically isolated from the lower housing component <NUM>, it may be easier to optimize the size, shape, materials, or other properties of the coating <NUM> for use as an antenna without having to consider the electrical effect of the remaining portions of the housing on the antenna performance.

The structural member <NUM> may be coupled to the lower housing component <NUM> using an adhesive or other bonding agent that forms a watertight seal therebetween. For example, an epoxy, cyanoacrylate, heat-sensitive adhesive (HAS), pressure-sensitive adhesive (PSA), or the like, may be used to form a watertight seal.

<FIG> are partial cross-sectional views of the housing <NUM> (or portions thereof), showing an example process of forming the housing <NUM>. <FIG> illustrates the structural member <NUM>. The structural member <NUM> may be formed by molding (e.g., injection molding) a polymer material, such as a polymer that is an electrical insulator.

At least a portion of the structural member <NUM> may then be coated with a conductive material <NUM>, as shown in <FIG>. The conductive material <NUM> may be coated on portions of the structural member <NUM> that ultimately form an exterior surface of the housing <NUM> and/or the electrical device that uses the housing <NUM>. In some cases, the conductive material <NUM> may be or may include the same material as the lower housing component <NUM>. For example, the conductive material <NUM> and the lower housing component <NUM> may both be or include aluminum, stainless steel, copper, or the like. In some cases, the conductive material <NUM> and the lower housing component <NUM> are different materials that have similar visual and/or tactile properties (e.g., surface finish, color, and texture). In other cases, the conductive material <NUM> differs from the material of the lower housing component <NUM> in these or other respects.

The conductive material <NUM> may be coated on, deposited on, or otherwise applied to the structural member <NUM> in any appropriate way. For example, the conductive material <NUM> may be applied to the structural member <NUM> by chemical vapor deposition, physical vapor deposition, printing (e.g., ink-jet printing with metallic inks), plating (e.g., electroplating, electroless plating), laser direct structuring, and the like. Where laser direct structuring is used, the structural member <NUM> may be formed from a material that is doped with a metal-plastic additive. A laser beam is then directed on the portions of the structural member <NUM> where the conductive layer <NUM> is to be formed, thereby forming a metal or metallized surface on the structural member <NUM>. The metal or metallized surface may then be further metallized using a plating technique such as electroplating or electroless plating to build the conductive layer <NUM> to a desired thickness.

The upper housing component <NUM> may be coupled to the lower housing component <NUM>. For example, an adhesive or bonding agent may be applied to one or both of the upper and lower housing components <NUM>, <NUM>, and the housing components may be brought into contact with each other. The adhesive or bonding agent may be selected so that the joint between upper and lower housing components <NUM>, <NUM> is watertight. Example adhesives include epoxy, cyanoacrylate, heat-sensitive adhesive (HAS), pressure-sensitive adhesive (PSA), or the like, may be used to form a watertight seal. In order to securely bond the lower housing component <NUM> to the structural member <NUM>, force may be applied to the structural member <NUM> and/or the lower housing component <NUM> after the adhesive is applied, such as with a clamp, vacuum bag, or other apparatus. The upper and lower housing components <NUM>, <NUM> may be coupled together before or after the conductive layer <NUM> is formed on the structural member <NUM>.

The coating of the conductive material <NUM> that is formed on the structural member <NUM> may be thicker than a desired final thickness of the conductive layer <NUM>. In such cases, some of the conductive material <NUM> may be removed with further processing or finishing operations to achieve a desired thickness. For example, as shown in <FIG>, a tool <NUM> may be used to grind or otherwise remove excess conductive material. The machining operation may remove all of the conductive material <NUM> in a certain location to expose the underlying structural member <NUM>. For example, the structural member <NUM> may define a protruding feature <NUM> that is flush with adjacent portions of the lower housing component <NUM> and the conductive layer <NUM> when the conductive material <NUM> is removed therefrom. When the finishing operation is complete, the protruding feature <NUM> may appear visually as a joint structure that is between an upper metal portion and a lower metal portion, despite the upper metal portion being a coating on the structural member <NUM>, as shown in <FIG>.

The tool <NUM> may be used to co-finish the lower housing component <NUM> and the upper housing component <NUM>. In particular, the same machining operation may be used along at least part of the lower housing component <NUM>, the conductive coating <NUM>, and the structural member <NUM> to produce a substantially uniform texture and/or appearance across the various different components and materials that define the exterior surface of the housing <NUM>. As shown in <FIG>, the co-finishing operation may include moving a rotating machine tool <NUM> (as indicated by the arrow <NUM>) along a path <NUM>, which will bring the tool into contact with the lower housing component <NUM>, the conductive coating <NUM>, and the structural member <NUM>.

<FIG> show a process for forming a housing that includes conductive housing components that are electrically isolated from each other by a joint structure. In particular, the process includes forming a housing blank that includes material from which the housing is to be formed in a pre-assembled configuration. More particularly, with reference to <FIG>, a housing blank may be formed by bonding a first conductive component <NUM>, a nonconductive component <NUM>, and a second conductive component <NUM> together to form a housing blank <NUM>. The first and second conductive components <NUM>, <NUM> may be formed from or include any appropriate conductive material, such as aluminum, steel, or the like. The nonconductive component <NUM>, which may ultimately electrically isolate portions of the housing <NUM> (<FIG>) from one another, may be formed from or include any appropriate nonconductive material, such as nylon, polyether ether ketone, polysulfone, polyphenylsulfone, polyaryletherketone, polyetherimide, polyethersulfone, or any other appropriate material.

The first and second conductive components <NUM>, <NUM> may be bonded to the nonconductive component <NUM> in any appropriate way. For example, an adhesive or other bonding agent may be applied to the components which are then laminated to form the housing blank <NUM>. In order to securely bond the conductive and nonconductive components, a force may be applied to the components after the adhesive is applied, such as with a clamp, vacuum bag, or other apparatus. Alternatively, the first and second conductive components <NUM>, <NUM> may be held in a spaced apart configuration and a material may be flowed, injected, or otherwise introduced between the conductive components <NUM>, <NUM>. The material may then be cured to form the nonconductive component <NUM> and bond the material to the conductive components <NUM>, <NUM>. Other potential techniques for bonding the first and second conductive components <NUM>, <NUM> to the nonconductive component <NUM> include diffusion bonding, ultrasonic welding, torsion welding, linear ultrasonic welding, insert molding, and friction welding.

The bond between the conductive components <NUM>, <NUM> and the nonconductive component <NUM> may be watertight. Thus, once the housing <NUM> (<FIG>) is formed from the housing blank <NUM>, the housing <NUM> itself may be watertight, at least along the seams or interfaces between the conductive components <NUM>, <NUM> and the nonconductive component <NUM>.

After the housing blank <NUM> is formed, material is removed from the housing blank <NUM> to form a housing <NUM> (<FIG>) having an exterior surface and an internal volume to receive electrical components, such as batteries, processors, and the like. Removing the material may include machining the housing blank <NUM> with a tool <NUM>, or any other appropriate process or operation such as laser ablation, plasma cutting, grinding, or the like. For example, as shown in <FIG>, the tool <NUM>, such as an end mill, may rotate as indicated by arrow <NUM> and move along the path <NUM> to at least partially define the inner volume. Other machining or material removal operations may also be used to form other aspects of the housing <NUM>, such as the angled interior corners of the internal volume and the rounded exterior surface.

The housing blank <NUM> is configured such that, after material is removed to form the housing <NUM>, a remaining portion of the nonconductive component <NUM> electrically isolates remaining portions of the first and second conductive components <NUM>, <NUM> from each other. For example, electrical isolation of the conductive components <NUM>, <NUM> may be useful where the portions of the conductive components <NUM>, <NUM> that remain after the machining operation act as an antenna or other component of an electrical circuit, as described above. Moreover, similar to the housings described above, at least portions of the first and second conductive components <NUM>, <NUM> as well as at least a portion of the nonconductive component <NUM> may define an exterior surface of the housing <NUM> after the housing blank <NUM> is machined to form the housing <NUM>.

<FIG> illustrate one example housing blank <NUM> and housing <NUM> that may be formed from the housing blank <NUM>. Where other geometries of a housing are desired, such as a different arrangement of housing components and joint structures, housing blanks having different structures may be used. For example, <FIG> show a process for forming a housing that is similar to the process described with respect to <FIG>, except the housing blank <NUM> (<FIG>) and the housing <NUM> produced therefrom (<FIG>) have a different structure. In particular, as shown in <FIG>, the housing <NUM> includes conductive housing components <NUM>. Each conductive housing component is electrically isolated from the others by the joint structure <NUM>, and may be used as an antenna or other component of an electrical circuit. In order to form the housing <NUM> with conductive components having a desired shape, size, and position, the housing blank <NUM> is configured to have a corresponding structure.

With reference to <FIG>, the housing blank <NUM> may be formed by bonding conductive components <NUM>, <NUM>, and <NUM> to a nonconductive component <NUM>. The nonconductive component may have protrusions, beams, arms, or other features that extend between the conductive components <NUM>, <NUM>, <NUM> to ensure electrical isolation between those components. As shown, beams <NUM> project from a base of the nonconductive component <NUM> and are each positioned between two conductive components. These features may result in joint structures positioned in desired positions between housing components in the final housing <NUM>.

As shown in <FIG>, the housing blank <NUM> may be machined or otherwise have material removed (e.g., with the tool <NUM> or any other appropriate material removal operation) to form the internal volume and exterior surface of the housing <NUM>, as shown in <FIG>. For example, as shown in <FIG>, the tool <NUM>, such as an end mill, may rotate as indicated by arrow <NUM> and move along the path <NUM> to at least partially define the inner volume. Other machining or material removal operations may also be used to form other aspects of the housing <NUM>, such as the angled interior corners of the internal volume and the rounded exterior surface.

Claim 1:
An electronic device (<NUM>), comprising:
a display;
a cover (<NUM>) over the display and defining a first portion of a front exterior surface of the electronic device (<NUM>); and
a housing (<NUM>) configured to receive the display and the cover (<NUM>), the housing (<NUM>) comprising:
a first conductive housing component (<NUM>) defining:
a first interface surface (<NUM>);
a first interlock feature (<NUM>) including a first recess formed into the first conductive housing component (<NUM>); and
a second portion of the front exterior surface of the electronic device (<NUM>), wherein the cover (<NUM>) is mounted to the first conductive housing component (<NUM>);
a second conductive housing component (<NUM>) defining:
a second interface surface (<NUM>) facing the first interface surface (<NUM>); and
a second interlock feature (<NUM>) including a second recess formed into the second conductive housing component (<NUM>); and
a back wall defining at least a portion of a back exterior surface of the electronic device;
a joint structure (<NUM>, <NUM>) between the first and second interface surfaces (<NUM>, <NUM>), comprising:
a molded element (<NUM>) defining:
a portion of a side exterior surface of the housing (<NUM>); and
first and second corresponding interlock features (<NUM>) engaged with the first and second interlock features (<NUM>), respectively, and fixing the first conductive housing component (<NUM>) to the second conductive housing component (<NUM>), the molded element (<NUM>) formed by introducing a joining material into the space between the first and second interface surfaces (<NUM>, <NUM>) and into the first and second recesses (<NUM>) and allowing the joining material to solidify to form the molded element (<NUM>); and
a sealing member (<NUM>) occupying a second portion of the space between the first and second interface surfaces (<NUM>, <NUM>) and abutting the molded element (<NUM>), wherein the sealing member (<NUM>) forms a watertight seal between the first conductive housing component (<NUM>) and the second conductive housing component (<NUM>).