PATENT DOCUMENT

Publication Number: US-10065289-B2
Application Number: US-201514842962-A
Country: US
Kind Code: B2

Title: Polishing features formed in components

Abstract:
A polishing system and method for polishing a channel formed within a component is disclosed. The polishing system may include a tooling element operable to be positioned within a recess formed partially through a component. The tooling element may include an outer surface having a geometry corresponding to a geometry of the recess formed in the component. The tooling element forms a channel between the recess of the component and the tooling element when positioned in the recess. The system may also include a first member in fluid communication with a first opening of the channel, and a second member in fluid communication with a second opening of the channel. The second opening may be in fluid communication with the first opening via the channel. Additionally, the first and second member may be configured to continuously vary a pressure within the channel to move an abrasive slurry within the channel.

Claims:
What is claimed is: 
     
       1. A method for polishing a component for a portable electronic device, the component having a non-linear surface, comprising:
 forming a channel having a first opening and a second opening between the non-linear surface of the component and a corresponding non-linear surface of a tooling element, wherein slurry is capable of moving within the channel; and 
 polishing the non-linear surface of the component by:
 (i) pushing the slurry from the first opening towards the second opening by using a first flexible member, the first flexible member covering the first opening, and 
 (ii) concurrent with pushing the slurry from the first opening towards the second opening, pulling the slurry towards the second opening by using a second flexible member, the second flexible member covering the second opening, wherein the non-linear surface is polished by movement of an amount of the slurry that is in polishing contact therewith. 
 
 
     
     
       2. The method of  claim 1 , wherein polishing the non-linear surface of the component further comprises:
 (iii) pushing the slurry from the second opening towards the first opening by using the second flexible member, and 
 (iv) concurrent with pushing the slurry from the second opening towards the first opening, pulling the slurry towards the first opening by using the first flexible member. 
 
     
     
       3. The method of  claim 2 , further comprising:
 repeating (i)-(iv) until the non-linear surface of the component is polished according to a predetermined amount. 
 
     
     
       4. The method of  claim 3 , wherein moving the slurry within the channel comprises:
 continuously varying a pressure within the channel using at least one of the first flexible member or the second flexible member; and 
 repeatedly moving the slurry from:
 the first opening to the second opening; and 
 the second opening to the first opening. 
 
 
     
     
       5. The method of  claim 1 , wherein the first flexible member is coupled to an outer surface of the tooling element and a surface of the component, and the second flexible member is coupled to the outer surface of the tooling element and the surface of the component. 
     
     
       6. The method of  claim 5 , wherein the component includes a recess that is formed partially through the component, and the recess includes a geometry that corresponds to the non-linear surface of the component and the corresponding non-linear surface of the tooling element. 
     
     
       7. The method of  claim 5 , wherein a portion of the outer surface of the tooling element is substantially planar to a portion of the surface of the component.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a nonprovisional patent application of and claims the benefit to U.S. Provisional Patent Application No. 62/044,862, filed Sep. 2, 2014 and titled “POLISHING CHANNELS FORMED WITHIN COMPONENTS,” the disclosure of which is hereby incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The disclosure relates generally to material polishing, and more particularly to a method and polishing system for polishing a feature (e.g., channels, recesses) formed within a component formed from substantially hard material. 
     BACKGROUND 
     Electronic devices continue to become more prevalent in day-to-day activities. For example, smart phones, tablet computers and electronic devices continue to grow in popularity and provide everyday personal and business functions to its users. These electronic devices may include housings to protect the internal components of the device. Additionally, the electronic device typical includes a cover glass for protecting a display of the device. The display may be utilized by the user to interact (e.g., through input/output operations) with the electronic device and/or receive information therefrom. 
     The use of ceramic-based materials, and specifically, the crystalline form of alumina (Al2O3) (e.g., corundum), commonly known as sapphire, may be used to form the housing and/or cover glass of the electronic device. With improved manufacturing processes of single crystal sapphire and the improved functional characteristics (such as hardness and strength) of sapphire, sapphire may be an acceptable replacement material for conventional housings or cover glass. However, the same chemical/elemental characteristics that make sapphire an often superior material choice over glass may also make the manufacturing of sapphire difficult. That is, due to sapphire&#39;s hardness, processing or shaping sapphire may be difficult. 
     For example, where the sapphire display includes curved or non-planar surfaces, conventional polishing techniques and processes may fall short of providing an adequate or desired polish on the curved or non-planar surfaces of the sapphire. Furthermore, small channels (e.g., recesses, through holes, and the like) formed through the sapphire component may be difficult to adequately polish using conventional polishing processes. Where the sapphire component is substantially thin to help reduce the overall size and weight of the electronic device, a conventional polishing process, such as diamond mechanical polishing (DMP), may also be too harsh on the sapphire component, and may potentially damage the sapphire. 
     SUMMARY 
     One embodiment described herein takes the form of a polishing system comprising: a tooling element operable to be positioned at least partly within a recess of a component and comprising an outer surface having a geometry corresponding to a geometry of the recess, the tooling element defining a channel within the recess; a first member in fluid communication with a first opening of the channel; and a second member in fluid communication with a second opening of the channel; wherein the second opening is in fluid communication with the first opening via the channel; and the first member and the second member are configured to continuously vary a pressure within the channel to move an abrasive slurry positioned within at least a portion of the channel. 
     Another embodiment takes the form of a structure comprising: a corundum-based component comprising: a body portion; and a recess formed partially though the body portion, the recess having a complex geometry; and a tooling element operable to be positioned within the recess, thereby defining, between the tooling element and the body portion, a channel within the recess; wherein the tooling element comprises an outer surface having a geometry corresponding to the complex geometry of the recess. 
     Still another embodiment described herein may take the form of a component having body portion and a first opening formed on the body portion. The component may also comprise a second opening formed on the body portion. The second opening may be in fluid communication with the first opening. The component may also comprise a uniformly polished channel fluidly coupling the first opening and the second opening. The uniformly polished channel may have a complex geometry, such as a curved portion, an angular portion and/or a non-linear portion. 
     Yet another embodiment takes the form of a method for polishing a surface of a channel formed in a component, comprising the operations of: forming a channel between a recess formed partially through a component and a tooling element positioned within the recess of the component, the tooling element comprising an outer surface having a geometry corresponding to a geometry of the recess; coupling a first member and a second member of a polishing system to at least one of the component and the tooling element to enable fluid communication with the channel; and flowing an abrasive slurry positioned within the channel over a surface of the recess between the first member and the second member, thereby polishing the surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  depicts an illustrative view of a component having a channel, according to embodiments; 
         FIG. 2  depicts a cross-section view, taken along line  2 - 2 , of the component of  FIG. 1  and a polishing system; 
         FIGS. 3A and 3B  depict cross-section views of the component of  FIG. 2  undergoing a polishing process performed by the polishing system; 
         FIG. 3C  depicts a cross-section view of the component of  FIG. 1  including a polished channel; 
         FIG. 4  depicts a cross-section of a component including a surface feature and a tooling element of a polishing system positioned within the recess; 
         FIG. 5A  depicts a cross-section view of the component of  FIG. 4  and a polishing system; 
         FIGS. 5B-5D  depict cross-section views of the component of  FIG. 4  undergoing a polishing process performed by the polishing system; 
         FIG. 5E  depicts a cross-section view of the component of  FIG. 4  including a polished channel; 
         FIG. 6  depicts a cross-section view of the component of  FIG. 4  and a polishing system including a gasket and a cutout tooling element; 
         FIG. 7  depicts a cross-section view of the component of  FIG. 4  and a polishing system including an actuator and a reservoir; 
         FIG. 8  depicts a cross-section view of the component of  FIG. 4  and a polishing system including two fluid pumps; 
         FIG. 9  depicts a cross-section view of the component of  FIG. 4  and a polishing system including a fluid pump and a vacuum chamber; and 
         FIG. 10  depicts a flow chart illustrating a method for polishing a surface of a channel formed in a component. 
     
    
    
     DETAILED DESCRIPTION 
     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 spirit and scope of the described embodiments as defined by the appended claims. 
     The following disclosure relates to a material polishing, and more particularly, to a method and polishing system for polishing a feature (e.g., channel, recess, or the like) formed within a component formed from substantially hard material. 
     In a particular embodiment, the polishing system may utilize an abrasive slurry positioned within a channel formed through the component and two distinct polishing components positioned on opposite sides of the channel. The two distinct polishing components may form a seal around the openings of the channel and may continuously vary a pressure within the channel to flow or otherwise move the abrasive slurry throughout the channel. As the abrasive slurry moves through the channel, it may contact and subsequently polish a sidewall or surface of the channel formed in the component. 
     In other embodiments, the component includes a recess in place of a through hole. In some embodiments, a channel may be formed between a surface of the recess and an exterior of a tooling element that may include or take the form of a corresponding geometry of the recess. The tooling element may be positioned within the recess formed in the component and may be positioned adjacent to the surface of the component to be polished. The tooling element includes a temporary and/or disposable insert or fill component that is positioned within the recess to form the channel between the component and the tooling element. The two distinct polishing components of the polishing system may be positioned on opposite openings of the channel formed between the recess and the tooling element, and may move or flow the abrasive slurry through the channel to polish the surface of the recess formed in the component. 
     These and other embodiments are discussed below with reference to  FIGS. 1-10 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1  is an illustrative view of a component  100 . That is,  FIG. 1  depicts a body portion  102  of a component  100  that may be utilized within or as part of an electronic device. In non-limiting examples, component  100  may be utilized to form a housing of the electronic device or a cover glass used to protect a display of the electronic device. The electronic device may include, but is not limited to, a tablet computing device, a smartphone, a gaming device, a display, a digital music player, a wearable computing device or display, a health monitoring device and so on. 
     Component  100  may be transparent or translucent, fully or partially, in certain embodiments. Component  100  may be formed from corundum, commonly referred to as sapphire. However, it is understood that component  100  may be formed from any suitable transparent material and/or combination of suitable transparent material including, but not limited to, ceramics, alumina, chemically strengthened glass and reinforced plastic. 
     As shown in  FIG. 1 , component  100  may include a feature, such as a component channel  104 . In a non-limiting example, channel  104  may be formed completely through body portion  102  of component  100 . That is, as shown in  FIG. 1 , a first opening  106  may be formed on a first or top surface  108  of body portion  102  and a second opening  110  may be formed on second or bottom surface  112  of body portion  102  of component  100 . First opening  106  and second opening  110  may be in fluid communication with one another via channel  104  formed through body portion  102 . 
     Channel  104  of component  100  may have a polished sidewall or component surface  118  when finished, incorporated into an electronic device, in an intermediate stage, and so on. The component surface  118  of channel  104  formed in component  100  may be polished for a variety of reasons including, but not limited to, aesthetics to smooth surface  118  for improved coupling to a distinct component within channel  104 , to minimize a frictional coefficient of surface  118  of channel  104  and the like. However, because of a reduced thickness of component  100  and/or component&#39;s  100  material composition, which may be susceptible to damage when undergoing a conventional polishing processes (e.g., sand blasting, water blasting and the like), channel  104  may be polished using a less oppressive process, as discussed herein. 
       FIG. 2  depicts a front cross-section view of component  100  taken along line  2 - 2  in  FIG. 1 . As shown in  FIG. 2 , a polishing system  120   a ,  120   b  may be coupled to component  100  and may be used to polish component surface  118  of channel  104 . In a non-limiting example, and as discussed in detail herein, a two-part polishing system  120   a ,  120   b  may be in fluid communication with channel  104  via first opening  106  and second opening  110 . In the non-limiting example and as discussed herein, polishing system  120   a ,  120   b  may be configured to move an abrasive slurry  122  positioned within a portion of channel  104  to polish component surface  118  of channel  104 . 
     As shown in  FIG. 2 , polishing system  120   a  may include a first member  124  positioned adjacent to first opening  106  of channel  104 . First member  124  may substantially cover first opening  106  of channel  104  and may be releasably coupled to a portion of top surface  108  of body portion  102  of component  100 . First member  124  may be coupled to a portion of top surface  108  using any suitable technique including, but not limited to applying an adhesive, forming a suction bond between top surface  108  and first member  124  and the like. As shown in  FIG. 2 , first member  124  of polishing system  120   a  may include a first flexible membrane  126  that may form an airtight and/or hermetic seal around first opening  106  of channel  104 . First flexible membrane  126  may be formed from a substantially flexible material that may allow first flexible membrane  126  to maintain the seal over first opening  106  and be actuated or deformed to change a pressure within channel  104 , as discussed herein. 
     Polishing system  120   a  may also include a first actuator  128  coupled to first flexible membrane  126 . As shown in  FIG. 2 , first actuator  128  may be coupled to first flexible membrane via shaft  130 . First actuator  128  may be coupled to first flexible membrane  126  to actuate or deform a portion of first flexible membrane  126  to change or vary a pressure within channel  104  during a polishing process, as discussed herein. First actuator  128 , as shown in  FIG. 2 , may be any suitable actuator that may actuate or deform first flexible membrane  126  in a direction (D) when performing a polishing process on channel  104  of component  100 . 
     As shown in  FIG. 2 , two-part polishing system  120   a ,  120   b  may include components positioned on the opposite end (e.g., second opening  110 ) of channel  104 . The components of polishing system  120   b  positioned on the opposite end or second opening  110  of channel  104  may be substantially similar to the components of polishing system  120   a  positioned adjacent to first opening  106  of channel  104 . In a non-limiting example shown in  FIG. 2 , polishing system  120   b  may include a second member  132  positioned adjacent to second opening  110  of channel  104 . Second member  132  may include a second flexible membrane  134  that may form a seal around second opening  110  of channel  104  and may be releasably coupled to a portion of bottom surface  112  of component  100 . Second flexible membrane  134  may be formed from a substantially similar material as first flexible membrane  126  having substantially flexible properties. 
     Polishing system  120   b  may also include a second actuator  136  coupled to second flexible membrane  134 . Second actuator  136  may be coupled to second flexible membrane  134  using shaft  130 . Similar to first actuator  128 , second actuator  136  may be coupled to second flexible membrane  134  to actuate or deform a portion of second flexible membrane  134  in a direction (D) to change or vary a pressure within channel  104  during a polishing process, as discussed herein. 
     Polishing system  120   a ,  120   b  may also include abrasive slurry  122 . As shown in  FIG. 2 , abrasive slurry  122  may be positioned within channel  104  of component  100 . In a non-limiting example, abrasive slurry  122  may fill a portion of channel  104  and may be sealed within channel  104  between first flexible membrane  126  and second flexible membrane  134  of polishing system  120   a ,  120   b . As discussed herein, abrasive slurry  122  may not completely fill channel  104  of component  100  in order for abrasive slurry  122  to flow over and polish component surface  118  during a polishing process. Abrasive slurry  122  may include a diamond encrusted resin-based material that may have elastic properties to avoid damaging the surface of the sapphire material when performing the polishing process. The elastic properties of abrasive slurry  122  may avoid damaging component  100  by substantially deforming when flowing along and/or contacting component surface  118  of channel  104  during the polishing process. Additionally, the elastic properties of abrasive slurry  122  may aid in achieving complete coverage of surface  118  of channel  104  with abrasive slurry  122  during the polishing process. 
     Although discussed herein as a slurry, it is understood that other distinct materials or media may be used in the polishing processed discussed herein. In non-limiting examples, the slurry may be formed from any suitable material having substantially elastic properties, such as an elastomer material. In other non-limiting examples, polishing system  120   a ,  120   b  may utilize an oil, a clay, a gelatin and so on for polishing channel  104  of component  100 . In the non-limiting examples, the material may be diamond encrusted and/or may include additional additives for providing abrasive properties to the material used to polish component  100 . 
       FIGS. 3A-3C  depict component  100  undergoing a polishing process using polishing system  120   a ,  120   b . That is,  FIGS. 3A-3C  depict component surface  118  of channel  104  formed in component  100  undergoing a polishing process using polishing system  120   a ,  120   b.    
     As shown in  FIG. 3A , polishing system  120   a ,  120   b  may be coupled to and/or in fluid communication with channel  104  via first opening  106  and second opening  110 , respectively, as discussed herein with respect to  FIG. 2 . Additionally, and as discussed herein with respect to  FIG. 2 , first flexible membrane  126  may form a seal around first opening  106  and second flexible membrane  134  may form a seal around second opening  110 . As a result of the seal being formed at the respective openings in component  100 , it is understood that channel  104 , having abrasive slurry  122  positioned therein, may have an evenly distributed internal pressure in a static state or when there is no movement of the components of polishing system  120   a ,  120   b.    
     However, as shown in  FIG. 3A , polishing system  120   a ,  120   b  may actuate or deform first flexible membrane  126  and/or second flexible membrane  134  to vary the pressure within channel  104 . First actuator  128  of polishing system  120   a  may actuate first flexible membrane  126  to move to a first actuator push position. As shown in  FIG. 3A , the push position of first flexible membrane  126  may deform or move a portion of first flexible membrane  126  within channel  104 , while maintaining first flexible membrane&#39;s  126  seal around first opening  106 . 
     Simultaneously, or substantially simultaneously, to first actuator  128  actuating first flexible membrane  126  to move to a first actuator push position, second actuator  136  of polishing system  120   b  may actuate second flexible membrane  134  to move to a second actuator pull position. As shown in  FIG. 3A , the pull position of second flexible membrane  134  may deform or move a portion of second flexible membrane  134  away from channel  104  and/or out of plane (shown in phantom) with bottom surface  112 , while maintaining second flexible membrane&#39;s  134  seal around second opening  110 . 
     By moving or actuating first flexible membrane  126  to a first actuator push position and moving second flexible membrane  134  to a second actuator pull position, the pressure within channel  104  may vary. In a non-limiting example shown in  FIG. 3A , when first flexible membrane  126  is in the push position and second flexible membrane  134  is in the pull position, a first force (F 1 ) or pressure flow may be applied within channel  104  toward second flexible membrane  134 . Actuating first flexible membrane  126  to the push position may result in a pressure force being applied in a direction away from first flexible membrane  126 . Additionally, actuating second flexible membrane  134  to the pull position may result in a pressure force or suction being applied in a direction toward second flexible membrane  134 . 
     As a result of the actuation of first flexible membrane  126  and second flexible membrane  134  and the resulting first force (F 1 ) or pressure flow, abrasive slurry  122  may be displaced within channel  104 . As shown in  FIG. 3A , as a result of the actuation of first flexible membrane  126  and second flexible membrane  134 , the first force (F 1 ) may change the pressure within channel  104  and may cause abrasive slurry  122  to be displaced throughout channel  104 . When displaced throughout channel  104 , abrasive slurry  122  may flow over surface  118  of channel  104  toward first flexible membrane  126  and/or opposite the direction of first force (F 1 ). As abrasive slurry  122  flows over surface  118 , abrasive slurry  122  may polish surface  118  of channel  104 . 
       FIG. 3B  shows polishing system  120   a ,  120   b  actuating or deforming first flexible membrane  126  and second flexible membrane  134  again to vary the pressure within channel  104 . That is, component  100  and polishing system  120   a ,  120   b  undergo an additional actuation process to polish surface  118  of channel  104  after the actuation process as shown in  FIG. 3A . 
     As shown in  FIG. 3B , first actuator  128  of polishing system  120   a  may actuate first flexible membrane  126  to a first actuator pull position. Similar to the discussions herein with respect to second flexible membrane  134  in  FIG. 3A , the first actuator pull position of first flexible membrane  126  may deform or move a portion of first flexible membrane  126  away from channel  104  and/or out of plane (shown in phantom) with top surface  108 , while maintaining first flexible membrane&#39;s  126  seal around first opening  106 . 
     Additionally, and simultaneously, or substantially simultaneously with actuating first flexible membrane  126  to a first actuator pull position, second actuator  136  may be actuated to a second actuator push position. As shown in  FIG. 3B , and similarly discussed herein with respect to first flexible membrane  126  in  FIG. 3A , the second actuator push position of second flexible membrane  134  may deform or move a portion of second flexible membrane  134  within channel  104 , while maintaining second flexible membrane&#39;s  134  seal around second opening  110 . 
     Similar to  FIG. 3A , by moving or actuating first flexible membrane  126  to a first actuator pull position and moving second flexible membrane  134  to a second actuator push position, the pressure within channel  104  may vary again. In the non-limiting example shown in  FIG. 3B , when first flexible membrane  126  is in the pull position and second flexible membrane  134  is in the push position, a second force (F 2 ) or pressure flow may be applied within channel  104  toward first flexible membrane  126 . Specifically, actuating second flexible membrane  134  to the push position may result in a pressure force being applied in a direction away from second flexible membrane  134 . Additionally, actuating first flexible membrane  126  to the pull position may result in a pressure force or suction being applied in a direction toward first flexible membrane  126 . 
     As a result of the actuation of first flexible membrane  126  and second flexible membrane  134  and the resulting second force (F 2 ) or pressure flow, abrasive slurry  122  may be displaced within channel  104  again. As shown in  FIG. 3B , as a result of the actuation of first flexible membrane  126  and second flexible membrane  134 , the second force (F 2 ) may change the pressure within channel  104  and may cause abrasive slurry  122  to be displaced throughout channel  104 . Similar to  FIG. 3A , when displaced throughout channel  104 , abrasive slurry  122  may flow over surface  118  of channel  104 . However, in the non-limiting example shown in  FIG. 3B , abrasive slurry  122  may flow or move toward second flexible membrane  134  and/or opposite the direction of second force (F 2 ). As abrasive slurry  122  flows over surface  118 , as shown in  FIG. 3B , abrasive slurry  122  may continue to polish surface  118  of channel  104 . 
     By continuously or repeatedly actuating first flexible membrane  126  and second flexible membrane  134  between the pull position and the push position, respectively, surface  118  may be polished to a desired finish. Specifically, as first flexible membrane  126  and second flexible membrane  134  are actuated between the pull position and the push position and abrasive slurry  122  continuously moves throughout or within channel  104  and over surface  118 , surface  118  may be polished. 
     As shown in  FIG. 3C , surface  118  of channel  104  of component  100  may include a polished portion  138 . Polished portion  138  of surface  118  of component  100  may be formed by actuating first flexible membrane  126  and second flexible membrane  134 , respectively, a predetermined amount of times and/or for a predetermined amount of time based on the material forming component  100 , the size of channel  104  and/or the desired polish to be formed on surface  118 . 
     Although depicted in  FIGS. 3A-3C  as only partially filling channel  104 , it is understood that abrasive slurry  122  may completely fill channel  104 . As similarly discussed herein, polishing system  120   a ,  120   b  may be operational to agitate abrasive slurry  122  completely filling channel  104  to polish surface  118  of channel  104 . 
       FIG. 4  depicts a cross-section view of a component  400  and a tooling element  140  of polishing system  120   a ,  120   b . Component  400  may be substantially similar to component  100  discussed herein with respect to  FIGS. 1-3C . Component  400  may include a body portion  402 , a top surface  408  and bottom surface  416 . Distinct from component  100 , component  400  may not include a channel formed completely through body portion  402 . Rather, as shown in  FIG. 4 , channel  404  may be formed between a recess  442  formed partially through body portion  402  of component  400  and tooling element  140 . Recess  442  formed partially through body portion  402  of component  400  may include surface  118  having a complex geometry including, but not limited to, one or more curved portions, angular portions and/or non-linear portions. Additionally, tooling element  140  may include an outer surface  144  having a complex geometry that may correspond to the complex geometry of surface  118 . When tooling element  140  is positioned within recess  442  of component  400 , channel  404  may be formed within and/or between component  400  and tooling element  140 . Additionally, as shown in  FIG. 4 , when tooling element  140  is positioned within recess  442  of component  400  to form channel  404 , exposed surface  146  of tooling element  140  may be aligned and/or planar with top surface  408  of component  400 . 
     Tooling element  140  includes a temporary and/or disposable insert or fill component that is positioned within recess  442  to form channel  404  between component  400  and tooling element  140 . In a non-limiting examples, and as discussed herein, tooling element  140  may be a substantially rigid insert and/or structure that may be suspended and/or positioned within recess  442  to create and/or form channel  404 . Tooling element is also a distinct component from component  400 , and is part of the polishing system used to polish channel  404 , as discussed herein. Tooling element  140  may be formed from any material that may substantially maintain channel  404  during a polishing process of component  400 . In a non-limiting example, tooling element  140  may be formed from a metal or metal alloy that may not substantially wear during the polishing process and/or may be cast to include a geometry corresponding to the geometry of surface  418  of component  400 . 
       FIGS. 5A-5E  depict component  400  undergoing a polishing process using polishing system  120   a ,  120   b . As one example,  FIGS. 5A-5E  depict surface  418  of channel  404  formed in component  400  undergoing a polishing process using polishing system  120   a ,  120   b . It is understood that similarly numbered components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
       FIG. 5A  shows component  400  prior to performing the polishing process. As shown in  FIG. 5A , polishing system  120   a ,  120   b  may be in fluid communication with channel  404  formed between body portion  402  and tooling element  140 . As similarly discussed herein with respect to  FIGS. 2-3B , first flexible membrane  126  of polishing system  120   a  may form a seal around first opening  406  of component  400  and second flexible membrane  134  of polishing system  120   b  may form a seal around second opening  410 . However, distinct from  FIGS. 2-3B , first flexible membrane  126  and second flexible membrane  134  may be coupled to the same surface. 
     As one example, and as shown in  FIG. 5A , first opening  406  and second opening  410  of channel  404  may be formed through top surface  408  of component  400 . As such, both first flexible membrane  126  and second flexible membrane  134  may be coupled to a portion of top surface  408  of component and exposed surface of tooling element  140  for forming seals around the respective openings of channel  404 . 
     Abrasive slurry  122  may be positioned within channel  404  of component  400 . As shown in  FIG. 5A , abrasive slurry  122  may be positioned within a portion of channel  404  of component  400  and may contact surface  418  of recess  442  of component  400 , as well as outer surface  144  of tooling element  140 . As discussed herein, abrasive slurry  122  may flow through channel  404 , contacting surface  418  of component, to form a polished portion  438  of component  400  (see,  FIG. 5E ). 
       FIG. 5B  depicts polishing system  120   a ,  120   b  actuating first flexible membrane  126  and second flexible membrane  134  to apply a first force (F 1 ) or pressure flow to channel  404 , toward second flexible membrane  134 . As shown in  FIG. 5B , and as similarly discussed herein with respect to  FIG. 3A , first flexible membrane  126  may be actuated to a push position and second flexible membrane  134  may be actuated to a pull position to apply a first force (F 1 ) through channel  404 . As a result of first force (F 1 ) being applied through channel  404  of component  400 , abrasive slurry  122  may be displaced or move through channel  404 , toward second opening  410  and/or second flexible membrane  134 . As discussed herein, abrasive slurry  122  may contact and/or polish surface  418  of channel  404  as abrasive slurry  122  moves through channel  404 . 
       FIG. 5C  depicts polishing system  120   a ,  120   b  actuating first flexible membrane  126  and second flexible membrane  134  to a neutral position. As shown in  FIG. 5C , first flexible membrane  126  may be actuated out of the push position and second flexible membrane  134  may be actuated out of the pull position and both flexible membranes  126 ,  134  may be in a neutral position. When in a neutral position, no force may be applied through channel  404 . As a result, the pressure within channel  404  of component  400  may return back to a static state and abrasive slurry  122  may settle at the bottom of recess  442  and/or channel  404  of component  400 . 
       FIG. 5D  depicts polishing system  120   a ,  120   b  actuating first flexible membrane  126  and second flexible membrane  134  to apply a second force (F 2 ) or pressure flow to channel  404 , toward first flexible membrane  126 . As shown in  FIG. 5B , and as discussed herein with respect to  FIG. 3B , first flexible membrane  126  may be actuated to the pull position and second flexible membrane  134  may be actuated to the push position to apply a second force (F 2 ) through channel  404 . As a result of second force (F 2 ) being applied through channel  404  of component  400 , abrasive slurry  122  may be displaced or move through channel  404 , toward first opening  406  and/or first flexible membrane  126 . As discussed herein, abrasive slurry  122  may contact and/or continue to polish surface  418  of channel  404  as abrasive slurry moves through channel  404 , as shown in  FIG. 5D . 
     Similar to  FIGS. 3A-3C , abrasive slurry  122  may continuously move within channel  404 , between first opening  406  and second opening  410 , by repeatedly actuating first flexible membrane  126  and second flexible membrane  134  between a push position and a pull position. As shown in  FIG. 5E , surface  418  of component  400  may have polished portion  438  after continuous actuation of the respective flexible membranes and/or the continuous movement of abrasive slurry  122  over surface  418 . Once polished portion  438  is formed on surface  418 , tooling element  140  may be removed from recess  442 , and component  400 , having polished portion  438 , may be ready for implementation within a device or system, as desired. 
     Although discussed herein with respect to  FIGS. 3A-3C and 5A-5E  as performing a polishing process using polishing system  120   a ,  120   b  on a single component (e.g., component  100 , component  400 ), it is understood that multiple components may be polished simultaneously by polishing system  120   a ,  120   b . Multiple components may be positioned adjacent one another (e.g., stacked, contacting, aligned) to polish multiple components in a single polishing process. Where applicable, tooling element  140  may also be configured or shaped to form a channel within multiple components (e.g.,  400 ), and provide only two openings for polishing system  120   a ,  120   b . As a result, abrasive slurry  122  may be moved between multiple components for polishing a surface (e.g., surface  118 ,  418 ) of channel  104 ,  404 . 
     Additionally, although tooling element  140  is discussed as only polishing a single component (e.g., component  100 , component  400 ), it is understood that tooling element  140  may be utilized to polish multiple components in succession. In a non-limiting example, tooling element  140  may be used to polish multiple components individually using polishing system  120   a ,  120   b , where the tooling element  140  is placed in each component prior to performing the polishing process, as discussed herein. 
       FIG. 6  depicts a cross-section view of component  400  and polishing system  120   a ,  120   b  according to another non-limiting embodiment. As shown in  FIG. 6 , the space surrounding first opening  406  and second opening  410  may be increased to allow for a greater pressure force and/or suction force to be applied to channel  404  of component  400  during a polishing process performed by polishing system  120   a ,  120   b . That is, by increasing the area of first opening  406  and/or second opening  410  of channel  404 , first flexible membrane  126  and/or second flexible membrane  134  may be actuated, moved or displaced a greater distance, which may increase the pressure force and/or suction force applied to channel  404 . 
     In an non-limiting example, as shown in  FIG. 6 , polishing system  120   a  may utilize a gasket  150  coupled to first flexible membrane  126 . Gasket  150  may be coupled to top surface  408  of component  400  and exposed surface  146  of tooling element  140  to form a seal around first opening  406 . Additionally, as shown in  FIG. 6 , gasket  150  may raise first flexible membrane  126  substantially above first opening  406 , and more specifically, may form a space  152  between first opening  406  and first flexible membrane  126 . Gasket  150  may allow first flexible membrane  126  to be actuated or displaced within space  152 . By actuating first flexible membrane  126  in space  152  formed by gasket  150 , a larger portion of first flexible membrane  126  may be actuated into space  152  when compared to first flexible membrane  126  being actuated directly into channel  404  (see,  FIG. 5B ). By increasing the portion of first flexible membrane  126  that is actuated, as well as, increasing the depth within space  152  that first flexible membrane  126  may be actuated, the force or pressure flow applied through channel  404  may also be increased. 
     In another non-limiting example, an opening of channel  404  may be increased by providing a cutout  154  in tooling element  140 . As shown in  FIG. 6 , the size of second opening  410  of channel  404  may be increased by providing cutout  154  in tooling element  140 , adjacent second opening  410 . Similar to space  152  formed by gasket  150 , cutout  154  of tooling element  140  may allow second flexible membrane  134  to be actuated or displaced a greater distance into channel  404  of component during a polishing process. By increasing the distance in which second flexible membrane  134  may be actuated or displaced, a force or pressure flow applied to channel  404  by second flexible membrane  134  may also be increased. 
     Although shown in  FIG. 6  to include distinct features for increasing actuation or displacement for each of the flexible membranes, it is understood that any combination of the features of  FIG. 6  may be used by polishing system  120   a ,  120   b . In a non-limiting example, both first flexible membrane  126  and second flexible membrane  134  may utilize gaskets  150 , or tooling element  140  may have cutouts  154  adjacent to first opening  406  and second opening  410 . Additionally, in another non-limiting example, both gaskets  150  and cutouts  154  on tooling element  140  may be used with polishing system  120   a ,  120   b.    
       FIG. 7  depicts a cross-section view of component  400  and a distinct polishing system  720   a ,  720   b  according to other non-limiting embodiments. Distinct from polishing system  120   b  discussed herein with respect to  FIGS. 5B and 5C , polishing system  720   b  may not include a second flexible membrane or a second actuator. Rather, as shown in  FIG. 7 , polishing system  720   b  may include a reservoir  756  forming a seal around second opening  410  of channel  404 . Reservoir  756  may maintain the air tight seal around channel  404 . Reservoir  756  may receive air and/or abrasive slurry  122  during the polishing process performed on channel  404  of component  400 . As first flexible membrane  126  is actuated to a push position, and a push force is applied to channel  404 , reservoir  756  may receive at least a portion of the forced air applied to channel  404  and/or a portion of abrasive slurry  122  flowing through channel  404  toward second opening  410 . In addition, when first flexible membrane  126  is actuated to a pull position, the suction force applied to channel  404  by first flexible membrane  126  may be applied to reservoir  756  as well. As a result, abrasive slurry  122  positioned within reservoir  756  may flow from reservoir  756  toward first flexible membrane  126 . 
       FIG. 8  depicts a cross-section view of component  400  and an additional polishing system  820   a ,  820   b  according to distinct, non-limiting embodiments. As shown in  FIG. 8 , polishing system  820   a ,  820   b  may not include actuators or flexible membranes. Rather, polishing system  820   a  may include a first pump  858  in fluid communication with first opening  406  of channel  404 . First pump  858  may be in fluid communication with first opening  406  via a first hose or conduit  860 . As shown in  FIG. 8 , first conduit  860  may be directly coupled to first pump  858  and first opening  406  of channel  404 . Additionally, as shown in  FIG. 8 , first conduit  860  may form a seal with first opening  406  to prevent leakage of air pressure or force provided by first pump  858  during a polishing process. To aid in the formation of the seal with first opening  406 , an O-ring  862  may be coupled to first conduit  860 , and may also be coupled to a portion of top surface  408  of component  400  and exposed surface  146  of tooling element  140 , to surround first opening  406 . First pump  858  may be any suitable air pump that may provide a pressure force to channel  404  via first conduit  860  during a polishing process, as discussed herein. 
     Also shown in  FIG. 8 , polishing system  820   b  may include similar components as polishing system  820   a . That is, polishing system  820   b  may include a second pump  864  in fluid communication with second opening  410  of channel  404  via second hose or conduit  866 . Second conduit  866  may form a seal with second opening  410  of channel  404  and may utilize O-ring  862  to aid in forming the seal. 
     When performing a polishing process using polishing system  820   a ,  820   b , abrasive slurry  122  positioned within channel  404  may be moved between first opening  406  and second opening  410  using first pump  858  and second pump  864 . That is, first pump  858  and second pump  864  of polishing system  820   a ,  820   b  may alternate providing a force or pressure flow through channel  404  to move or flow abrasive slurry  122  through channel  404  to contact and subsequently polish surface  418 . In a non-limiting example, first pump  858  may be operable to provide a push force through channel  404  to move abrasive slurry  122  through channel  404  toward second opening  410 . Simultaneously, second pump  864  may be inoperable to provide no pressure flow to channel  404  or may be throttled to provide an minimal pressure flow to channel  404  that may be overcome or negligible when push force is applied to channel  404  by first pump  858 . Once abrasive slurry  122  reaches second opening  410 , the respective pumps of polishing system  820   a ,  820   b  may switch operational states. That is, second pump  864  may provide a push force through channel  404  to move abrasive slurry  122  through channel  404  toward first opening  406  and first pump  858  may be inoperable or throttled to allow push force of second pump  864  to move or flow abrasive slurry toward first opening  406 . As similarly discussed herein, first pump  858  and second pump  864  may repeatedly alternate operational states to continuously move or flow abrasive slurry  122  through channel  404 , and over surface  418 , to ultimately form polished portion (see,  FIG. 5E ) on surface  418  of channel  404 . 
       FIG. 9  depicts a cross-section view of component  400  and an additional polishing system  920   a ,  920   b  according to distinct, non-limiting embodiments. Distinct from polishing system  820   a  discussed herein with respect to  FIG. 8 , first pump  858  of polishing system  920   a  may provide a continuous flow of abrasive slurry  122  through channel  404  during a polishing process. First pump  858  may be in fluid communication with a supply tank  968  of abrasive slurry  122 . During a polishing process, first pump  858  may supply a continuous flow of abrasive slurry  122  from supply tank  968  to channel  404  through first opening  406 . The continuous flow of abrasive slurry  122  supplied by first pump  858  may flow completely through channel  404 , contacting and polishing surface  418 , and may leave channel  404  via second opening  410 . 
     Also distinct from polishing system  820   b  discussed herein with respect to  FIG. 8 , polishing system  920   b  may not include second pump  864  coupled to second conduit  866 . Rather, as shown in  FIG. 9 , polishing system  920   b  may include a vacuum chamber  970  in fluid communication with second opening  410  of channel  404 . Vacuum chamber  970  may be in fluid communication with second opening via second conduit  866 , which may form a seal with second opening  410 , as discussed herein. Vacuum chamber  970  may provide a suction force within channel  404  of component  400  during a polishing process performed by polishing system  920   a ,  920   b . In a non-limiting example, as first pump  858  of polishing system  820   a  supplies a continuous flow of abrasive slurry  122  through channel  404 , vacuum chamber  970  may provide a suction force within channel  404  to aid in drawing abrasive slurry  122  through channel  404  and second opening  410 . As shown in  FIG. 9 , an optional slurry recycling conduit  972 , shown in phantom, may fluidly couple vacuum chamber  970  and supply tank  968 . During the polishing process, the abrasive slurry  122  removed from channel  404  by vacuum chamber  970  may flow through slurry recycling conduit  972  to supply tank  968 , to be reused or resupplied to channel  404  by first pump  858 . The utilization of slurry recycling conduit  972  may form a closed loop polishing process where a finite amount of abrasive slurry  122  may be continuously used to form polished portion on surface  418  of component  400 . 
     Although discussed herein as a channel or recess, it is understood that the feature of the component may include distinct and unique geometries as well. In a non-limiting example not shown, the component may include a protrusion that may require polishing. A surface of the protrusion of the component may be polished using similar devices (e.g., tooling element, first member, second member and the like) and similar processes (e.g., tooling element having corresponding geometry, flowing abrasive slurry and so on) discussed herein. 
     Turning to  FIG. 10 , a method for polishing a surface of a channel formed in a component (see,  FIG. 1 ) is now discussed. Specifically,  FIG. 10  is a flowchart depicting one sample method  1000  for polishing a surface of a channel, as discussed herein with respect to  FIGS. 1-9 . 
     In operation  1002 , a channel may be formed between a recess formed partially though a component and a tooling element positioned within the recess of the component. The tooling element may have an outer surface having a geometry that may correspond to a geometry of the recess formed in the component. 
     In operation  1004 , a first member and a second member of a polishing system may be coupled to at least one of the component and the tooling element. The coupling of the first member and the second member to the component and/or the tooling element may enable fluid communication with the channel formed between the component and the tooling element. The coupling of the first member may also include forming a seal around a first opening of the channel formed between the recess and the tooling element. The seal formed around the first opening of the channel may prevent air from escaping from the channel. Additionally, the coupling of the second member may include forming a seal around a second opening of the channel formed between the recess and the tooling element. The second opening may be in fluid communication with the first opening. The seal formed around the second opening of the channel may prevent air from escaping from the channel, similar to the first member and first channel. 
     In operation  1006 , an abrasive slurry may be flowed over the surface of the channel between the first member and the second member of the polishing system. That is, an abrasive slurry, formed from a diamond encrusted resin-based material, may flow over the surface of the channel to polish the surface of the channel. The flowing of the abrasive slurry over the surface of the channel may also include passing the abrasive slurry over the surface of the channel having a complex geometry. The complex geometry of the channel may be a curved, angular and/or non-linear, among other options. 
     The flowing of the abrasive slurry over the surface of the channel may be performed in a variety of processes dependent, at least in part, upon the configuration of the first member and the second member of the polishing system. In a non-limiting example the flowing of the abrasive slurry may include continuously varying a pressure within the channel using the first member and/or the second member of the polishing system. By continuously varying the pressure within the channel, the abrasive slurry may repeatedly move from the first opening to the second opening, and back, from the second opening to the first opening. 
     The flowing of the abrasive slurry may also include supplying a continuous flow of the abrasive slurry to the channel using the first member. That is, the first member of the polishing system may supply a continuous flow of the abrasive slurry to the surface of the channel. Additionally, in the non-limiting example, the second member may vacuum the continuous flow of the abrasive slurry supplied by the first member. That is, the second member may provide a vacuum force through the channel and to the abrasive slurry to move the supplied abrasive slurry through the channel from the first opening to the second opening. As the abrasive slurry moves through the channel of the component, the surface of the channel may be polished. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20150902
Publication Date: 20180904
Grant Date: 20180904
Priority Date: 20140902
Inventors: CHINNAKARUPPAN, PALANIAPPAN
KAMIREDDI, SRIKANTH
Assignee: APPLE INC
CPC Classifications: [{"code": "B24B31/116", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C1/08", "inventive": true, "first": true, "tree": "[]"}, {"code": "B24B31/116", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C3/327", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C3/327", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C1/083", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24B31/006", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C3/32", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C3/32", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C1/083", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C1/08", "inventive": true, "first": true, "tree": "[]"}, {"code": "B24B31/116", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C3/32", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C1/08", "inventive": true, "first": true, "tree": "[]"}, {"code": "B24C3/327", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24C1/083", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24B31/006", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 55401432