Patent ID: 12238882

DETAILED DESCRIPTION

The following disclosure describes various embodiments of electronic devices, such as portable electronic devices including, for example, cellular telephones, and the like. Certain details are set forth in the following description and FIGS. to provide a thorough understanding of various embodiments of the present technology. Moreover, various features, structures, and/or characteristics of the present technology can be combined in other suitable structures and environments. In other instances, well-known structures, materials, operations, and/or systems are not shown or described in detail in the following disclosure to avoid unnecessarily obscuring the description of the various embodiments of the technology. Those of ordinary skill in the art will recognize, however, that the present technology can be practiced without one or more of the details set forth herein, or with other structures, methods, components, and so forth.

The accompanying FIGS. depict several features of embodiments of the present technology and are not intended to be limiting of its scope. Many of the details, dimensions, angles, and other features shown in the Figures are merely illustrative of particular embodiments of the disclosure. Accordingly, other embodiments can have other details, dimensions, angles, and/or features without departing from the spirit or scope of the present disclosure.

An electronic device can include several components assembled together to form internal and/or external features of the electronic device. For example, one or more internal components (e.g., electrical circuitry and/or internal support structures) can be placed within external components (e.g., housing structures) to provide an electronic device having desired functionality. As used herein, the term “component” refers to a distinct entity of an electronic device. Components may include, for example, electronic circuit elements (e.g., a microchip), one or more members forming the housing of the electronic device (e.g., a backplate or an outer periphery component), and internal support structures (e.g., a mid-plate).

In some cases, a component can be manufactured by assembling and connecting two or more different individual elements (i.e., “sections”) together. As used herein, the term “section” can refer to an individual portion of a component, where that component may be formed from multiple sections. The various sections of the component may then be coupled together using a “coupling member.” For example, the electronic device may include an enclosure component assembled from two or more sections, which are joined together with one or more coupling members.

Based on the desired functionality and design of the component and its sections, these coupling members can exhibit a wide range of shapes and structures. For example, the coupling members can include structural elements that can reinforce areas of high mechanical strain, counteract twisting movements at areas of high torsion, interlock two sections together such that they are mechanically coupled together, provide electrical isolation between two or more sections, and the like.

FIG.1is a schematic perspective view of an electronic device10. Electronic device10may be any one of a number of electronic devices including, but not limited to, cellular telephones, smartphones, other wireless communication devices, personal digital assistants, audio players, video players, game players, other media players, music recorders, video recorders, cameras, other media recorders, radios, medical devices, vehicle transportation instruments, calculators, programmable remote controls, pagers, laptop computers, desktop computers, printers, and combinations thereof. In some cases, electronic device10may perform multiple functions (e.g. play music, display video, store pictures, and receive and transmit telephone calls).

In the illustrated embodiment, electronic device10includes a body11incorporating a display12. Display12can include a cover or cover glass14that is operably coupled to a frame, housing, or enclosure16. In certain embodiments, display12may allow a user to interact with or control electronic device10. For example, display12and/or cover glass14can include touch-sensitive features to receive input commands from a user. In various embodiments, a cover or cover glass can encompass most of the surface area (e.g., 50%-100%) of one side of electronic device10(as shown inFIG.1), and a cover or cover plates can be positioned on an opposing side of electronic device10(not shown). As described in detail below, enclosure16and the cover glass14can at least partially house or enclose several internal components of the electronic device. According to some embodiments, cover glass14may be made from a glass (e.g., a pigmented or non-pigmented aluminosilicate glass) or other suitable material (e.g., sapphire).

In the embodiment illustrated inFIG.1, enclosure16also at least partially defines several additional features of the electronic device10. In particular, the enclosure16can include audible speaker outlets18, a connector opening20, an audio jack opening22, a card opening24(e.g., SIM card opening), a front facing camera26. Though not shown inFIG.1, enclosure16may also include a rear facing camera, a power button, and one or more volume buttons. AlthoughFIG.1schematically illustrates several of these features, one of ordinary skill in the art will appreciate that the relative size and location of these features can vary.

In certain embodiments, enclosure16can be made from a metallic material. For example, enclosure16can be made from aluminum or an aluminum alloy such as 6063 Aluminum. In other embodiments, however, enclosure16can be made from other materials, including suitable metals, alloys, and/or plastics.

As shown inFIG.1, enclosure16can include opposing edge portions30(identified individually as a first edge portion30aand a second edge portion30b) extending around a periphery of the body11. In certain embodiments, one or both of edge portions30can have a chamfered, beveled, or other suitably shaped profile. As described in detail below, edge portions30may be formed to provide an aesthetically appealing appearance for enclosure16.

According to some embodiments, the exterior surface of enclosure16can be exposed to a first treatment, edge portions30may be formed, and the exterior surface of enclosure16, including edge portions30, can be exposed to a second treatment. In one embodiment, for example, a first anodization process can be applied to enclosure16before edge portions30are chamfered, and a second subsequent anodization process can be applied to enclosure16after edge portions30have been chamfered. Additional suitable surface treatments, including intermediary surface treatments, can be applied to enclosure16and/or edge portions30. In still further embodiments, edge portions30can have other suitable profiles or shapes including and/or surface treatments.

According to some embodiments, the anodization processes referred to above can be similar to those disclosed in co-pending U.S. Ser. No. 13/332,288, filed Dec. 20, 2011, entitled “METAL SURFACE AND PROCESS FOR TREATING A METAL SURFACE,” which is incorporated by reference herein in its entirety. In some embodiments, the anodization processes can be similar to those disclosed in U.S. patent application Ser. No. 13/610,813, filed Sep. 11, 2012, entitled, “DOUBLE ANODIZING PROCESSES,” the disclosure of which is incorporated by reference herein in its entirety. For example, the processes can include applying a mask to a portion of a metal surface (e.g., a portion of enclosure16) using a photolithographic process. After the mask is applied, the metal surface can be exposed to one or more texturizing processes, including machining, brushing, blasting, or chemically etching the surface.

Further, the metal surface can be exposed to an anodization process, which can convert a portion of the metal surface into a metal oxide for increased corrosion resistance, wear resistance, and or to obtain a desired cosmetic effect (e.g., colorization via absorption of dyes or metals). The anodization process may be performed before or after the photolithographic mask is removed. In some embodiments, a first photolithographic mask can be removed and a second photolithographic mask can be applied before performing the anodization process. In still further embodiments, and as described above, the metal surface may be exposed to more than one anodization process. One or more finishing processes (e.g., polishing or sealing) may also be performed on the metal surface. In some embodiments, a first portion of the housing may be exposed to a first anodization process and a second portion of the housing may be exposed to a second anodization process.

FIG.2is a schematic perspective view of a subassembly40of electronic device10ofFIG.1. In the embodiment illustrated inFIG.2, subassembly40includes enclosure16coupled to a cover glass, such as the cover glass14shown inFIG.1. As shown inFIG.2, enclosure16can include a first enclosure section42coupled to a second enclosure section44, which is in turn coupled to a third enclosure section46. Additionally, enclosure16can include a first coupling member48that couples first enclosure section42to second enclosure section44at a first interface43. Enclosure16can also include a second coupling member50that couples second enclosure section44to third enclosure section46at a second interface45. As assembled, subassembly40forms a five-sided structure, or tub, that can be enclosed on its sixth side by cover glass14.

In certain embodiments, the first, second, and third enclosure sections42,44, and46can be metallic, and the first and second coupling members48and50can be made from one or more plastic materials. As described below in detail, for example, each of the first and second coupling members48and50can be formed from a two-shot molding process that may include a first plastic portion that joins the corresponding enclosure portions and a second cosmetic plastic portion that at least partially covers the first plastic portions. As further described in detail below, these plastic portions can be configured to withstand harsh chemicals and manufacturing processes (e.g., the texturizing and anodization processes described above) that may be used to form and process the enclosure. In further embodiments, the enclosure sections42,44, and46and/or the first and second coupling members48and50can be made from any suitable materials including metallic, plastic, and/or other materials.

According to additional features of the embodiment illustrated inFIG.2, enclosure16can include one or more low resistance conductive portions52(shown schematically) for grounding purposes. Conductive portion52can be formed by removing one or more layers or portions of the enclosure16to provide a lower resistance through enclosure16for antenna transmissions or communications. In certain embodiments, for example, the conductive portion52can be formed by laser etching or otherwise removing or etching an anodized portion of enclosure16. The exposed surfaces of conductive portion52can then be chemically treated to retain its electrical conductivity. Examples of suitable chemical treatment include chromate and non-chromate conversion coatings to passivate conductive portion52. These coatings can be applied using techniques including spraying and brushing using a paint brush. The conductivity of conductive portion52, as well as through different portions of enclosure16, can be tested using suitable techniques such as using resistance using probes at different points of conductive portion52and enclosure16to assure that ground can be established though enclosure16.

The illustrated subassembly40also includes several inserts54that can provide increased structural support and functionality for enclosure16. In embodiments in which the enclosure16is formed from aluminum, for example, inserts54can increase strength and durability of enclosure16by providing mounting points for structural and/or functional internal components. Additionally, in certain embodiments, inserts54can include threaded inserts or nuts that are configured to threadably engage a corresponding fastener. Inserts54formed from titanium may be advantageous as titanium can withstand harsh manufacturing processes and chemicals to which subassembly40may be subjected. In other embodiments, however, inserts54can be made from other suitable materials including, for example, steel, stainless steel, or brass.

According to yet additional features of the subassembly40not visible inFIG.2, but described in detail below with respect toFIGS.10,11, and15, cover plates can be securely coupled, and offset if desired, relative to one side of the five-sided enclosure16. In particular, the cover plates can be aligned with a reference plane or datum relative to enclosure16. In order to maintain tight tolerance between the cover plates and enclosure sections42,44, and46, enclosure16can include one or more access openings56that may be used to urge or bias the cover plates relative to the enclosure16for secure attachment (e.g., an adhesive attachment). For example, one or more springs may be inserted through access openings56to bias the cover plates against a planar structure until an applied adhesive sets.

FIG.3shows a top view of an outer periphery component100of an electronic device in accordance with some embodiments. In particular,FIG.3shows a view of outer periphery component100, which may be assembled from sections110,120, and130. Outer periphery component100may generally represent a more detailed view of subassembly40ofFIG.2. For example, top section110, center section120, and bottom section130may correspond to first enclosure section42, second enclosure section44, and third enclosure section46, respectively. Outer periphery component100can be constructed to form an exterior, peripheral surface for an electronic device. In particular, outer periphery component100can surround or enclose some or all of the internal components (e.g., electronic circuits, internal support structures, and the like) of the electronic device. In other words, outer periphery component100can define an internal volume into which internal components can be placed.

The thickness, length, height, and cross-section of outer periphery component100may be selected based on any suitable criteria including, for example, structural requirements (e.g., stiffness or resistance to bending, compression, and tension or torsion in particular orientations). In some embodiments, outer periphery component100can serve as a structural member to which other electronic device components can be mounted. Some of the structural integrity of outer periphery component100can come from the closed shape that it defines (e.g., outer periphery component100forms a loop, thus providing structural integrity).

Outer periphery component100can have any suitably shaped cross-section. For example, outer periphery component100can have a substantially rectangular cross-section. Each corner of the substantially rectangular cross-section can be chamfered or rounded in shape, thus forming a “spline.” As used herein, the term “spline” refers to a rounded corner portion of an outer periphery component. In some embodiments, outer periphery component100can have a cross-section in any other suitable shape including, for example, a circular shape, an oval shape, a polygonal shape, or a curved shape. In some embodiments, the shape or size of the cross-section of outer periphery component100can vary along the length or width of the electronic device (e.g., an hourglass shaped cross-section). The spline may be formed by trimming one or more edges of outer periphery component100as described in detail below with respect toFIG.4.

Outer periphery component100of the electronic device can be constructed using any suitable process. In some embodiments, outer periphery component100can be constructed by connecting top section110and center section120together at interface112, and connecting center section120and bottom section130together at interface122. Although outer periphery component100is illustrated inFIG.3as being constructed from three sections, one skilled in the art could appreciate that outer periphery component100could alternatively be formed from any suitable number of two or more sections, and that the interfaces between the sections may be positioned at any location on outer periphery component100.

Each section110,120, and130can be constructed individually and later assembled to form outer periphery component100. For example, each section can be individually constructed using one or more of stamping, machining, working, casting, extrusion, or any combinations of these. In some embodiments, the materials selected for sections110,120, and130can be conductive, thus allowing the sections to provide an electrical functionality for the electronic device. For example, sections110,120, and130can be formed from a conductive material such as stainless steel or aluminum. In one particular embodiment, sections110,120, and130may be constructed from 6063 Aluminum. In some embodiments, each section may serve as an antenna for the electronic device.

To mechanically couple individual sections together, coupling members114and124can exist at interfaces112and122, respectively. In some embodiments, each of the coupling members can be constructed from a material that can begin in a first state and may subsequently change to a second state. As an illustration, the coupling members can be constructed from a plastic that begins in a first, liquid state and then subsequently changes to a second, solid state. For example, the coupling members may be formed using one or more injection molding processes.

In some embodiments, the coupling member can be constructed from a glass-filled polyethylene terephthalate (“PET”). Alternatively, the coupling member can be constructed from a high-strength plastic such as polyaryletherketone (“PAEK”) or polyether ether ketone (“PEEK”). While in the liquid state, the plastic can be allowed to flow into interfaces112and122. After flowing into these interfaces, the plastic material may subsequently be allowed to harden into coupling members114and124(e.g., the plastic material is allowed to change into the second, solid state). Upon changing into the solid state, the plastic material may then physically bond top section110to center section120along a first edge of center section120, and center section120and bottom section130along a second edge of center section120, thus forming a single new component (e.g., outer periphery component100).

Coupling members114and124not only physically couple together sections110and120, and sections120and130; they may also electrically isolate top section110from center section120, and center section120from bottom section130. As will be explained in more detail below, coupling members114and124may include locking structures that are attached to integrally formed parts of sections110,120, and130. That is, when the coupling member is in its first state (e.g., the liquid state), it can flow into and/or around the locking structures of section110,120, and/or130. A shutoff device (e.g., an insert mold, not shown) may be positioned at each interface to shape the coupling member for when it transforms into its second state (e.g., the solid state).

Coupling members114and124can be constructed to span a width of outer periphery component100, as shown inFIG.3. A portion of the coupling members114and124can interface with locking members existing on the sidewalls of sections110,120, and130, and other portions of coupling members114and124can interface with additional locking members existing on the edge of the sections. In some embodiments, the physical coupling between coupling members114and124and sections110,120, and130may be reinforced with one or more fasteners.

FIG.4shows a perspective view of the back side of outer periphery component100in accordance with some embodiments. Outer periphery component can include top section110, center section120, bottom section130, and interfaces112and122. As can be seen inFIG.4, center section120can form three sides of the five-sided outer periphery component100, which can form a tub shape. The three sides of center section120can include a planar region120a, a first sidewall120s, and a second sidewall (not visible). The sidewalls may extend perpendicularly from planar region120a.

Top section110and bottom section130can each be U-shaped members that include outer surfaces110aand130a, respectively. Top section110and bottom section130can also include inner surfaces (not shown). As assembled into outer periphery component100, a plane co-planar with planar region120aof section120can be perpendicular to any plane that is co-planar with outer surfaces110aand130aof sections110and130.

Also visible inFIG.4are cover plates170aand170b, which will be discussed in more detail below with respect toFIGS.10and11. Cover plates170aand170bmay be coupled to outer periphery component100such that outer surfaces171aand171bare flush with an outer surface of at least one side of outer periphery component100(e.g., an outer surface of center section120). Cover plates170aand170bmay each encompass any suitable surface area on the side of outer periphery component100(e.g., 1% to 50%).

Outer periphery component100can also include chamfered edges116aand116b. As noted above, chamfered edges can have any suitable shape (e.g., chamfer, round, or ogee), thus giving outer periphery component100any suitable cross-sectional shape. Chamfered edges116aand116bmay be aesthetically and tactilely pleasing features for outer periphery component100.

According to some embodiments, chamfered edges116aand116bmay be formed after one or more molding processes that are used to create one or more coupling members114and124. For example, top section110and center section120may be coupled together with coupling member114at interface112. Excess material from the molding of the coupling members that extends beyond the outer surface of outer periphery component100may be ground down, and outer periphery component100can be exposed to one or more finishing processes (e.g., anodization, texturization, or polishing).

One or more sections of the coupling members may then be machined to ready outer periphery component100for a second molding process, which can form cosmetic outward facing components for the coupling members. Excess material from the second molding process may be removed (e.g., ground down), and then chamfered edges116aand116bcan be machined, trimmed, ground, or otherwise processed to produce a desired edge profile (e.g., a chamfered edge profile). For example, the excess material from the second molding process may be removed in a co-finishing process such that the material is flush with chamfered edges116aand116b, planar region120a, first sidewall120s(and the second sidewall, not visible), and outer surfaces110aand130aof sections110and130, respectively. After chamfered edges116aand116bare formed, outer periphery component100may be exposed to one or more additional finishing processes (e.g., a second anodization process).

FIG.5shows detailed cross-sectional view of a portion of outer periphery component100taken along line A-A′ ofFIG.4. In particular,FIG.5shows a cross-sectional view of coupling member114, top section110, and a portion of center section120of outer periphery component100. Coupling member114(and coupling member124, which is not shown in this detailed view of outer periphery component100) can be constructed to include a first-shot component114aand a second-shot component114b.

Coupling members114and124(not shown) can be exposed to various physically and chemically harsh environments during the manufacturing process. For example, the side walls and back plate of an electronic device can undergo polishing or lapping operations, which can involve the use of very acidic (around pH 2) and/or very alkali (around pH 8-9) slurries depending on whether the polishing is a fine or rough polishing procedure. In addition, during a photolithography process, the device can be exposed to UV light during UV curing stage and developing stage, as well as exposure to a strong base such as sodium hydroxide for rinsing away non-cured photoresist material. Furthermore, during an anodizing process, the device can be subjected to a variety of acidic and alkali solutions at elevated temperatures and for extended amounts of time, as described above with reference to anodizing techniques. If a blasting, or other texturizing, procedure is used, the plastic material can be exposed to a pressurized blasting media. Additionally, during de-masking (used to remove photoresist material) the device can be exposed to acidic or alkali rinses solutions at elevated temperatures. Moreover, during a CNC the device can be exposed to cutting fluids. The first shot and second shot materials can be unaffected by one or more of the above described processes in that they can maintain structural integrity and can appear substantially unmarred. It should be noted that in some embodiments a mask can be used to prevent degradation of portions of plastic during some of the processes described above. For example, a mask can be used to protect plastic during higher intensity UV exposure during photolithography and during certain CNC steps to protect the plastic surface from scratching. Any suitable mask to protect the plastic can be used. In one embodiment, a UV curable polymer mask is used.

In embodiments described herein the materials used to form coupling members114and124, can be configured to withstand some or all the above described physical and chemical conditions. First-shot component114aand second-shot component114bcan be made of different materials to serve different functions. In some embodiments, the first-shot component114acan be formed from a relatively stronger material so as to provide structural support for the electronic device and second-shot component114bcan be formed from a softer but more cosmetically appealing material for aesthetic purposes. In certain embodiments, both first-shot component114aand second-shot component114bcan be configured to withstand some or all of the above described physical and chemical conditions. For example, first-shot component114aand second-shot component114bcan be formed from a high mechanical strength thermoplastic polymer resin such as a glass-filled PAEK or PEEK material. In other embodiments a glass-filled PET material can be used. In preferred embodiments, second-shot component114bcan appear smooth and even, thereby providing a more cosmetically appealing appearance than first-shot component114a. In some cases, the second-shot component114bcan take on any of a number of colors.

First-shot component114acan be responsible for physically coupling together the sections (e.g., section110and section120) of outer periphery component100and can be machined to include retaining regions for receiving the second shot. Second-shot component114bcan function as a cosmetic component that is self-anchored within the retaining region of first-shot component114a. Second-shot component114bmay be the only part of coupling member114that is visible to the user when the device is fully assembled. Because second-shot component114bmay be visible and exposed to the environment, including during one or more harsh processing steps, it can be formed from a material suitable for maintaining an aesthetically pleasing appearance (e.g., polyether imide (“PEI”)) notwithstanding such processing. Additionally, second-shot component114bcan have any suitable color.

According to some embodiments, first-shot component114acan be injection molded between top section110and center section120. In particular, top section110and center section120can be inserted into an injection mold (not shown), and the material for forming first-shot component114acan be injected into the mold cavity. In some embodiments, the injection mold may define one or more features and/or boundaries of first-shot component114a, including one or more of elements161-167and/or coupling member edge115. Alternatively, elements161-167and/or coupling member edge115can be formed (e.g., by grinding, machining, or otherwise trimming first-shot component114a) after the material has cooled and set.

Coupling member114(and coupling member124, not shown) may be machined, for example, to have holes, recesses, retention features, or any other desired features after it is applied as a first shot. Such machined features are illustratively shown as elements161-167. For example, elements161-164are holes, and elements165-167are rectangular cutouts. These machine features may enable cables to pass from one side of the coupling member to another or to enable secure placement of various components such as a button, a camera, a microphone, a speaker, an audio jack, a receiver, a connector assembly, or the like. Additionally, one or more of elements161-164can be an antenna window via which an antenna can radiate and/or receive signals.

FIG.6shows an exploded view of the detailed view of coupling member114, top section110, and center section120of outer periphery component100shown inFIG.5. First-shot component114acan include interface features141-147for interfacing with locking mechanisms151-159of sections110and120. According to some embodiments, interface features141-147may be formed during a first-shot injection molding process in which the material that forms first-shot component114afills the interstices that define locking mechanisms151-159of sections110and120.

According to some embodiments, coupling member114can interface with sidewall locking mechanisms151-154and edge locking mechanisms155-157with sidewall interface features141-144and edge interface features145-147, respectively. In some embodiments, sidewall interface features141-144can be referred to as “knuckles.” In particular, sidewall interface features141and143can form a first knuckle, and sidewall interface features142and144can form a second knuckle. Edge interface features, on the other hand can be formed on a “span” of coupling member114, which extends between the two knuckles. When coupling member114is applied in a liquid state (e.g., into an injection mold), it can flow into and/or around locking mechanisms151-157. When the material sets and turns into a solid as coupling member114, it can form a physical interconnect that couples sections110and120together. Coupling member114can include fastener through-holes148and149that line up with holes and or inserts in section110such that screws or other fasteners can be used to secure coupling member114to section110.

First-shot component114amay also include second-shot cavities140for receiving second-shot components114b. Second-shot cavities140may form recesses in first-shot component114aat the interfaces between section110and section120(as well as section120and section130, not shown). According to some embodiments, second-shot cavities140may be formed after first-shot component114ahas been formed. In particular, portions of first-shot component114acan be removed (e.g., by sawing, drilling, or machining) to form the recesses for second-shot cavities140.

Portions of sections110and120abutting first-shot component114amay also be removed when forming second-shot cavities140. For example, second-shot cavities140can be created by sawing material away from first-shot component114a, section110, and section120at the interfaces between sections110and120. Accordingly, the width of second-shot cavities140can be repeated with accuracy, as the width is determined solely by the kerf of the saw. Accuracy and repeatability in the formation of second-shot cavities140may be advantageous for a number of reasons including, for example, antenna performance and aesthetic considerations. In some embodiments, a relatively small amount (e.g., 0.05-0.15 mm) of material may be removed from each of sections110and120during the formation of second-shot cavities140.

Both second-shot cavities140may be formed at the same time. In particular, in embodiments in which second-shot cavities140are formed by sawing first-shot component114a, and/or portions of sections110and120, second-shot cavities140can be cut together. Additionally, the same cut that forms second-shot cavities140can remove material from section120across the width of outer periphery component100between the second-shot cavities140. Accordingly, a straight, clean edge can be formed at the edge of section120, resulting in excellent alignment between the various components of outer periphery component100.

In further embodiments, second-shot cavities140may be formed as first-shot component114ais molded (e.g., using features included in the injection mold). Second-shot components114bmay be purely cosmetic and configured to withstand harsh processing and/or chemicals while maintaining an attractive outward aesthetic.

In still further embodiments, coupling member114may include only first-shot component114a, with second-shot component114bbeing formed integrally with first-shot component114a. That is, coupling member114may be formed from a one-shot molding process, and the material that forms first-shot component114amay be visible from the outside of outer periphery component100. These embodiments may be preferable, for example, if the material used to form first-shot component114ais aesthetically pleasing even after exposure to one or more harsh chemicals and/or processes.

FIG.7shows a perspective view of extruded sections710,720, and730of an electronic device housing in accordance with some embodiments. Extruded sections710,720, and730may be cut from extruded parts that are later machined to form sections110,120, and130, as discussed above. In some embodiments, extruded sections710,720, and730can be extruded separately in order to simplify the machining processes that will form sections110,120, and130. Alternatively, two or more of extruded sections710,720, and730may be cut from the same extruded part and cut to size (e.g., the relative sizes shown inFIG.7). For example, top extruded section710and bottom extruded section730may both be cut from the same extruded part. In some embodiments, one or more of extruded sections710,720, or730may be bent during or after extrusion.

According to some embodiments, extruded sections710,720, and730may be assembled such that the longitudinal extrusion axis (i.e., the axis along which the section was extruded) of at least one of the sections (e.g., top extruded section710and bottom extruded section730) is perpendicular to the longitudinal extrusion axis of at least one other section (e.g., center extruded section720). For example, the longitudinal extrusion axes of top extruded section710and bottom extruded section730may be parallel to the z-axis, while the longitudinal extrusion axis of center extruded section720may be parallel to the y-axis. One or more of extruded sections710,720, and730may be oriented differently in order to facilitate machining of extruded sections710,720, and730into, for example, sections110,120, and130. For example, it may be difficult or impossible to form the five-sided tub structure of outer periphery component100of from a single extruded part or multiple extruded parts oriented along the same longitudinal extrusion axis.

One consequence of orienting one or more sections along different longitudinal extrusion axes is that visible grains, which are typical byproducts of extrusion processes, may not match between adjacent sections of the assembled electronic device. Accordingly, the materials and extrusion parameters used to form extruded sections710,720, and730, as well as the final orientations of the sections, may be optimized to minimize the appearance of grain boundaries between adjacent sections. As just one example, extruded sections710,720, and730may be formed from a material that is not susceptible to forming visual stretch marks during the extrusion process (e.g., 6063 Aluminum). Accordingly, extruded sections710,720, and730may appear to have a smooth, continuous, unibody aesthetic after the extruded sections are machined and assembled. In particular, the five-sided outer periphery component100, which can be assembled from sections110,120, and130, may appear to be one continuous, unibody component.

Assembling an electronic device housing from separate extruded sections (e.g., extruded sections710,720, and730) can be advantageous in several respects. For example, forming sections of an electronic device housing from extruded parts can be a cost effective and environmentally friendly alternative to conventional methods (e.g., die casting or molding) as the extrusion process can create long lengths of extruded parts that cut to appropriate lengths without excessive waste. Additionally, the availability of separately extruded sections can allow for the formation of detailed locking features (e.g., edge locking mechanisms155-157and sidewall locking mechanisms151-154ofFIG.6and retention holes860ofFIG.8), which may not be possible if the housing is formed from a single molded part.

FIG.8shows a perspective view of a portion of outer periphery component100of an electronic device including one or more retention holes860formed therethrough in accordance with some embodiments. As shown inFIG.8, one or more of section120, coupling member114, and section110may include one or more retention holes860formed therethrough (or partially therethrough). For example, retention holes860may be machined or otherwise formed through the material of center section120between a top surface120tand a bottom surface120b(not shown) of section120. Alternatively, retention holes860may extend only partially into the section120without reaching or extending through bottom surface120b.

In some embodiments, section120can be made from aluminum or an aluminum alloy (e.g., 6063 Aluminum), which may not be suitable for forming threads for receiving a screw. Therefore, the interior surface860iof retention holes860may be substantially continuous and smooth, and thus may not be suitable for receiving and retaining a screw mechanism. A threaded insert870may be positioned within and retained by retention hole860such that a screw mechanism may be threadably retained within a portion of outer periphery component100.

As shown inFIGS.9A and9B, a threaded insert870may be positioned within retention hole860. Threaded insert870can include one or more elements for receiving a fastener. For example, threaded insert870can include threads872for receiving and retaining a screw880. Threaded insert870may be made of any material (e.g., titanium) suitable for receiving and gripping screw880and withstanding harsh chemicals and/or processes (e.g., texturization and/or anodization).

Titanium may be particularly suitable for threaded insert870, because while titanium can anodize under the conditions used for anodizing aluminum, it will anodize only minimally and create little film growth. Thus, the titanium inserts will remain conductive and therefore suitable for electrical grounding, for example, even after undergoing an aluminum anodizing process. In addition, since anodization will occur minimally on titanium, the geometry of any threaded regions of the inserts may remain substantially the same. It should be noted that in addition to titanium, other suitable hard metals materials can be used for the threaded insert870, including magnesium, zinc, tantalum, or hard aluminum alloys such as 7075 Aluminum. Inserts made of softer aluminum alloys can be used, however the softer aluminum inserts may anodize in the aluminum anodizing bath. Therefore, in order to keep the aluminum inserts electrically conductive and to retain any threaded geometry, it can be necessary to mask the aluminum inserts using, for example polymer plugs, prior to exposure to the anodizing bath. However, this masking process can add time, cost, and manual labor to the process.

Threaded insert870may include a cap874that may be coupled to a body875. In some embodiments, cap874and body875can be integrally formed. The external surfaces of threaded insert870may be sized and shaped similarly to the size and shape of the internal surfaces of retention hole860such that threaded insert870can be positioned within retention hole860. For example, threaded insert870may be press fit into retention hole860(e.g., in the direction of arrow D). In some embodiments, an adhesive may be used to retain threaded insert870within retention hole860.

In some embodiments, at least a portion of cap874may have a larger cross-sectional area than a portion of body875. A top portion862of retention hole860may be larger than the remainder of retention hole860, such that top portion862may receive cap874and prevent cap874from being passed through the remainder of retention hole860. Moreover, cap874may include one or more protrusions873that may be received by one or more complimentary notches863in top portion862of retention hole860. When each protrusion873of cap874is aligned with and positioned within a respective notch863in top portion862of retention hole860, the interaction of each protrusion873and notch863may prevent threaded insert870from rotating with respect to retention hole860(e.g., in the direction of arrow S).

Threaded insert870may also include a threaded hollow876that may extend through at least a portion of cap874and/or through at least a portion of body875. The interior surface of threaded hollow876may include one or more threads872that may receive and retain complimentary threads882of a screw880that is rotated down into threaded hollow876(e.g., in the direction of arrow S). As mentioned, due to the interaction of each protrusion873and notch863, threaded insert870may be prevented from rotating within retention hole860in the direction of arrow S while screw880may be rotated within threaded hollow876of threaded insert870in the direction of arrow S. By positioning threaded insert870within retention hole860(e.g., of section120) screw880may be screwed into and at least partially retained by threaded insert870within retention hole860such that screw880can couple section120(via threaded insert870) to another component of the electronic device assembly (not shown).

FIG.10shows a perspective view of outer periphery component100including cover plates170aand170b. After coupling members114and124have coupled top section110to center section120and center section120to bottom section130, respectively, cover plates170aand170bmay be coupled to a bottom side of coupling members114and124, respectively. Cover plates170aand170bmay be formed from any suitable material or combination of materials (e.g., pigmented glass, white ceramic glass, or sapphire) that may protect one or more components positioned within outer periphery component100. The material that forms cover plates170aand170bmay be chosen for having a number of desirable qualities, including high strength, stiffness, and hardness or scratch resistance, transparency to radio frequencies, and/or opaqueness to visible light. The material also may be chosen based on aesthetic considerations (e.g., whether the color of the cover plate coordinates well with other colors of the electronic device incorporating outer periphery component100that are visible to a user).

According to some embodiments, cover plates170aand170bmay be formed from a pigmented glass (e.g., pigmented aluminosilicate glass). The pigmented glass may be opaque to visible light in order to hide one or more internal components housed within outer periphery component100including, for example, coupling members114and124. In these embodiments, the pigmented glass can be treated with one or more processes to improve its hardness and stiffness. For example, the pigmented glass can be exposed to a potassium nitrate bath, which can initiate an ion exchange process that strengthens the glass.

Additionally, one or both sides of cover plates170aand170b(e.g., outer surfaces171aand171band/or their respective opposing sides) formed from pigmented glass may be painted. Painting one or both sides of cover plates170aand170bwith a dark paint can ensure that the cover plates are, indeed, opaque and add consistency between cover plates manufactured in different batches, lots, plants, etc. Cover plates170aand170bmay be formed from pigmented glass in order to match dark colored features included elsewhere in outer periphery component100and/or the finished electronic device (e.g., electronic device10ofFIG.1).

According to some further embodiments, cover plates170aand170bmay be formed from a ceramic glass material. A base glass for forming the ceramic glass may be a glass (e.g., aluminosilicate glass) with several nucleation sites disposed throughout. The nucleation sites may be formed from any suitable impurity introduced into the base glass. The base glass can then be transformed into ceramic glass by exposure to one or more temperature cycling processes (e.g., raising and lowering the temperature of the base glass), which can promote crystal formation around the nucleation sites, thus forming the ceramic glass. In some embodiments, the ceramic glass may be an opaque, light colored (e.g., white, off white, or light gray) material. In these embodiments, the ceramic glass can be treated with one or more processes to improve its hardness and stiffness. For example, the ceramic glass can be exposed to a sodium nitrate bath, which can initiate an ion exchange process that strengthens the glass.

As with the pigmented glass, one or both sides of cover plates170aand170bformed from ceramic glass may be painted. Painting one or both sides of cover plates170aand170bwith a light (e.g., white, off white, or gray) paint can ensure that the cover plates are opaque and add consistency between cover plates manufactured in different batches, lots, plants, etc. Cover plates170aand170bmay be formed from ceramic glass in order to match light colored features included elsewhere in outer periphery component100and/or the finished electronic device (e.g., electronic device10ofFIG.1).

According to still further embodiments, although they may be opaque to visible light frequencies (e.g., 390-750 THz), cover plates170aand170bmay be transparent to light at frequencies (e.g., 500-6500 MHz) used for wireless communication. Accordingly, cover plates170aand170bmay be used as antenna windows that allow antennas disposed proximate thereto to radiate and receive wireless signals.

According to some embodiments, cover plates170aand170bcan be sliced to the appropriate thickness and cut to the appropriate lateral dimensions for incorporation into outer periphery component100. Cover plates170aand170bmay also be exposed to one or more polishing steps (e.g., before and/or after the sodium or potassium nitrate strengthening baths).

Furthermore, it may be aesthetically and tactilely advantageous for outer surfaces171aand171bof cover plates170aand170bto be flush with outer surface121of section120. Accordingly, to ensure that outer periphery component100has a smooth and continuous outer surface, one or more springs or biasing mechanisms may be provided through coupling members114and124for supporting cover plates170aand170bwith respect to coupling members114and124while an adhesive is allowed to set. The adhesive can adhere cover plates170aand170bto coupling members114and124, for example.

As shown inFIG.11, one or more springs or biasing mechanisms1104(e.g.,1104a-c) may be passed through holes125in coupling member124towards the underside of cover plate170bto bias cover plate170bagainst a flat datum surface1100. Outer surface121of section120may also be held against flat datum surface1100. According to some embodiments, each biasing mechanism may be independently controlled by its own biasing module1102(e.g.,1102a-c) such that different portions of cover plate170bmay be biased with different biasing forces against flat datum surface1100for ensuring that all portions of outer surface171bof cover plate170bmay be flush or in a continuous plane with outer surface121of section120while an adhesive (not shown) is allowed to dry. The adhesive may secure cover plate170bto coupling member124and/or section120and/or section130.

FIG.12shows an illustrative process1200for creating a housing for an electronic device in accordance with some embodiments. Beginning at step1201, three separate sections of a housing can be formed. The three separate sections can include a top section, a center section, and a bottom section. According to some embodiments, the three separate sections may be extruded along a longitudinal extrusion axis and cut to the appropriate length (e.g., the lengths of extruded sections710,720, and730ofFIG.7). The three separate sections may be formed from a metallic material (e.g., aluminum, 6063 Aluminum, stainless steel, or any other suitable metal or alloy). One skilled in the art will appreciate that the housing for the electronic device may be assembled from any suitable number of sections (e.g., 2-5).

At step1203, each extruded section can be machined to include locking members and/or other suitable features. The locking members can be formed along one or more edges (e.g., edge locking mechanisms155-157ofFIG.6) and/or sidewalls (e.g., sidewall locking mechanisms151-154ofFIG.5) of each section. According to some embodiments, each extruded section may also be machined to reduce the thickness of the walls of the extruded sections. The walls of each extruded section may be machined to a thickness that will optimize the interior volume of the electronic device assembled from the sections while retaining suitable structural integrity.

At step1205, a first section is coupled to a second section with a first coupling member. Similarly, at step1207, the second section can be coupled to a third section with a second coupling member. For example, as shown inFIG.3, top section110can be coupled to center section120with coupling member114, and center section120can be coupled to bottom section130with coupling member124. According to some embodiments, the coupling members can be formed at the same time (e.g., during a first-shot injection molding process). Accordingly, the three separate sections can be set within a mold, and the injection molding material (e.g., a suitable liquid plastic material such as PAEK or PEEK) can be injected into the mold. The injection molding material may be permitted to flow into one or more of the locking members of the sections and allowed to set, physically coupling the sections together. As an alternative, each of the coupling members can be formed separately.

At step1209, the first and second coupling members can be machined to form cosmetic cavities. Because the first and second coupling members may be responsible for adding structural support to the electronic device housing, the material that forms the coupling members may be chosen primarily for its strength. Accordingly, aesthetic considerations may be a secondary concern for the coupling members. However, as part of the coupling members may be visible on the exterior of the electronic device (e.g., at interfaces112and122ofFIG.4), the portions of the coupling members that will be visible can be machined to create cosmetic cavities, (e.g., cavities suitable for receiving second-shot molded members). The second-shot material may be chosen primarily for its aesthetic qualities.

At step1211, cosmetic structures can be formed in the cosmetic cavities. According to some embodiments, the cosmetic structures may be formed in the cosmetic cavities using a second-shot injection molding process. As the cosmetic structures may be visible from the exterior of the electronic device, a suitable material (e.g., PEI) may be chosen for its ability to maintain a pleasing aesthetic appearance even after exposure to one or more harsh chemicals (e.g., sulfuric acid and nitric acid) and/or processes (e.g., UV light exposure and anodization). After the cosmetic structures are formed, one or more grinding or sanding processes may shape the cosmetic structures such that they are flush with the outer surfaces of the housing.

At step1213, first and second cover plates (e.g., cover plates170aand170bofFIG.10) can be fixed to the first and second coupling members, respectively. The first and second cover plates may be affixed to the first and second coupling members such that outer surfaces of the cover plates are co-planer with at least one outer surface of one of the sections (e.g., outer surface121of section120). Alternatively, the cover plates may be offset by a desired distance from the datum surface defined by an outer surface of one of the sections.

According to some embodiments, one or more edges of the housing may be machined, trimmed, or otherwise altered to form an aesthetically and tactilely pleasing profile. For example, opposing edge portions30ofFIG.1can be machined to create chamfered edges. According to some embodiments, the edges can be machined after the cosmetic structures are formed at step1211. For instance, after the cosmetic structures are molded and shaped as described above, the edges of the housing (and portions of the cosmetic structures) can be machined to form a desired edge profile (e.g., a chamfered edge profile). After the edges are machined, the housing may be exposed to one or more finishing processes (e.g., anodization). Accordingly, both the material that forms the housing (e.g., 6063 Aluminum) and the material that forms the cosmetic structures (e.g., PEI) may be chosen to withstand, and maintain a pleasing external appearance, through the finishing processes.

FIG.13shows an illustrative process1300for creating a housing for an electronic device in accordance with some embodiments. Beginning at step1301, three separate sections of a housing can be formed. The three separate sections can include a top section, a center section, and a bottom section. According to some embodiments, the three separate sections may be extruded along a longitudinal extrusion axis and cut to the appropriate length (e.g., the lengths of extruded sections710,720, and730ofFIG.7). The three separate sections may be formed from a metallic material (e.g., aluminum, 6063 Aluminum, stainless steel, or any other suitable metal or alloy). One skilled in the art will appreciate that the housing for the electronic device may be assembled from any suitable number of sections (e.g., 2-5).

At step1303, at least one section can be machined to include retention holes (e.g., retention holes860ofFIG.8). The retention holes may extend from a top surface of a section through a bottom surface (e.g., top surface120tand bottom surface120bof section120ofFIG.9A). Alternatively, the retention holes may extend through the top surface of the section without reaching the bottom surface.

At step1305, a first section can coupled to a second section with a first coupling member. Similarly, at step1307, the second section can be coupled to a third section with a second coupling member. For example, steps1305and1307may substantially correspond to steps1205and1207as described above with respect toFIG.12.

At step1309, the first and second coupling members can be machined to form holes corresponding to the retention holes of the at least one section. In particular, holes can be formed in the first and second coupling members at points where the coupling members overlap retention holes that were formed at step1303. In some embodiments, step1303may be omitted, and retention holes can be formed in at least on section and through the coupling members simultaneously (e.g., in step1309). According to certain embodiments, a top section of the retention holes may be larger than the remainder of the retention holes. Furthermore, one or more notches may be formed in the top sections of the retention holes.

At step1311, threaded inserts (e.g., threaded insert870ofFIG.9A) may be placed into the retention holes. The threaded inserts may have outer dimensions that correspond to the dimensions of the retention holes. For example, if the retention holes include top sections with wider cross-sectional areas than the remainder of the retention holes, the threaded inserts may have include a cap (e.g., cap874ofFIG.9A) with a cross-sectional area corresponding to the top sections of the retention holes and a body (e.g., body875ofFIG.9A) with a cross-sectional area corresponding to the remainder of the retention holes. According to some embodiments, the cap of the threaded insert can include one or more protrusions (e.g., protrusions873ofFIG.9A) that correspond to notches in the top sections of the retention holes.

The threaded inserts may include a threaded hollow (e.g., threaded hollow876) that may extend through at least a portion of the cap and/or through at least a portion of the body. The interior surface of the threaded hollow may include one or more threads (e.g., threads872ofFIG.9A) that may receive and retain complimentary threads of a screw (e.g., threads882of screw880ofFIG.9B) that can be rotated down into the threaded hollow. In some embodiments the threaded inserts may be formed from a metal (e.g., titanium). According to some embodiments, the threaded inserts may be press fit into the retention holes and/or affixed within the retention holes using an adhesive.

At step1313, fasteners (e.g., screws) may be retained within the threaded inserts. The fasteners may be used to mount or otherwise couple one or more internal components of the electronic device to the sections of the housing. For example, one or more circuit boards, structural reinforcing members, cameras, and/or other suitable internal components may be mounted within the electronic device housing assembled from the sections.

FIG.14shows an illustrative process1400for creating a housing for an electronic device in accordance with some embodiments. At step1401, at least one section of the housing can be extruded. According to some embodiments, a single member can be extruded along a longitudinal extrusion axis cut to lengths appropriate for the sections of the housing of the electronic device. For example, extruded sections710,720, and730ofFIG.7may be cut from a single extruded member. In other embodiments, any of the sections of the housing can be extruded separately. For example, extruded sections710,720, and730can each extruded separately and cut to length or extruded sections710and730may be cut from the same extruded member and center extruded section720may be extruded separately.

The sections may be formed from any suitable material (e.g., aluminum, 6063 Aluminum, stainless steel, or plastic). According to some embodiments, however, the material and various extrusion parameters (e.g., extrusion rate, temperature, etc.) may be chosen to minimize the appearance of any stretch marks or grains resulting from the extrusion process. For example, 6063 Aluminum may be chosen for the material. Accordingly, when the sections are joined together, the housing can appear to be of a seamless, unibody construction without noticeable grain boundaries between the sections.

At step1403, each extruded part can be machined to the desired dimensions of the housing. For example, the extruded parts can be machined to form sections110,120, and130ofFIG.3. In particular, the thickness of the each extruded part can be machined to a thickness that can optimize the interior volume of the electronic device housing assembled from the sections while retaining suitable structural integrity. Other features may also be formed in the extruded parts at step1403, including one or more retention holes (e.g., retention holes860ofFIG.8) and/or locking members (e.g., locking members151-157ofFIG.6).

According to some embodiments, steps1401and1403may be combined. In particular, a single member can be extruded along a longitudinal extrusion axis and machined to form the desired dimensions of the housing. For example, a single member in the shape of a rectangular prism may be extruded and then material can be removed (e.g., by machining) to form the housing. The housing can be a five-walled, tub shaped housing with a rectangular, planar surface and four sidewalls extending perpendicularly from the rectangular, planar surface as depicted schematically inFIG.2, for example. In some embodiments, the single member can be cut into individual sections (e.g., sections710,720, and730) before or after machining. Furthermore, additional material may be removed from one or more of the sections to form a window in the rectangular, planar surface.

At step1405, the sections can be rotated such that the longitudinal extrusion axis of at least one of the sections is oriented perpendicular to the longitudinal extrusion axis of at least one other section. For example, the longitudinal extrusion axes of two of the sections (e.g., top section110and bottom section130) may be oriented perpendicular to the longitudinal extrusion axis of a third section (e.g., center section120ofFIG.3).

At step1407, the sections can be physically coupled together using one or more coupling members to create the housing of the electronic device. This step may be substantially similar to those described in steps1205and1207ofFIG.12.

FIG.15shows an illustrative process1500for creating a housing for an electronic device in accordance with some embodiments. At step1501, cover plates can be coupled to coupling members accessible via a back side of an electronic device housing. For example, cover plates170aand170bcan be coupled to coupling members114and124, respectively, of outer periphery component100ofFIG.10. According to some embodiments, the cover plates can be coupled to the electronic device housing with an adhesive (e.g., an epoxy).

At step1503, the electronic device housing can be placed against a planar datum surface. For example, to ensure that the outer surfaces of the cover plates are flush with an outer surface of the electronic device housing (e.g., outer surfaces of171aand171bof cover plates170aand170bare flush with outer surface121of section120ofFIG.10), the outer surfaces can be placed against a planar datum surface (e.g., flat datum surface1100ofFIG.11). The planar datum surface can be any flat surface external to the electronic device.

At step1505, the electronic device housing, including the cover plates, can be biased against the planar datum surface with one or more biasing mechanisms. For example, the electronic device can be biased against the planar datum surface with any suitable external force (e.g., a biasing mechanism such as a spring or gravity). Additionally, the cover plates can be biased against the planar datum surface with one or more biasing mechanisms (e.g., springs). The biasing mechanisms (e.g., biasing mechanisms1104a-c) may be passed through holes (e.g., holes125in coupling member124) towards the underside of the cover plates to the cover plates against the flat datum surface1100. According to some embodiments, each biasing mechanism can be separately controlled by a biasing module (e.g., biasing modules1102a-c) such that different portions of the cover plates may be biased with different biasing forces against the flat datum surface to ensure that the outer surfaces of the cover plates and the outer surface of the electronic device are flush. At step1507, the adhesive may be allowed to dry while the electronic device housing is biased against the planar datum surface.

It should be understood that the processes described above are merely illustrative. Any of the steps may be removed, modified, or combined, and any additional steps may be added or steps may be performed in different orders, without departing from the scope of the invention.

The described embodiments of the invention are presented for the purpose of illustration and not of limitation.