PATENT DOCUMENT

Publication Number: US-10207387-B2
Application Number: US-201514714876-A
Country: US
Kind Code: B2

Title: Co-finishing surfaces

Abstract:
A method for co-finishing surfaces bonds a first structure formed of a first material and having a first surface in an aperture defined in a second structure formed of a second material and having a second surface such that there is an offset between the first surface and the second surface. The first surface and the second surface are co-lapped to reduce the offset. The first surface and second surface are co-polished to further reduce the offset. The first surface and second surfaces may then be flush. Edges of the first surface may be chamfered to mitigate damage during co-lapping and/or co-polishing. Fill material may be positioned in gaps between the first and second structures to mitigate damage during co-lapping and/or co-polishing.

Claims:
We claim: 
     
       1. A method for co-finishing surfaces, comprising:
 bonding a first structure formed of a first material and having a first surface in an aperture defined in a second structure formed of a second material and having a second surface such that there is an offset between the first surface and the second surface, the first structure having a chamfered edge; 
 co-lapping the first surface and the second surface to reduce the offset; and 
 co-polishing the first surface and the second surface such that the first surface and the second surface are flush; wherein: 
 at least one of the operation of co-lapping or the operation of co-polishing removes the chamfered edge. 
 
     
     
       2. The method of  claim 1 , further comprising chamfering an edge of the first surface prior to the operation of co-lapping, thereby forming the chamfered edge. 
     
     
       3. The method of  claim 1 , wherein at least one of the operation of co-lapping or the operation of co-polishing changes a shape of the first surface. 
     
     
       4. The method of  claim 1 , further comprising filling a gap between the bonded first structure and a side of the aperture. 
     
     
       5. The method of  claim 1 , wherein the second material comprises zirconia and the first material comprises one of glass, chemically strengthened glass, zirconia, alumina, and sapphire. 
     
     
       6. The method of  claim 1 , wherein the operation of co-polishing polishes the first surface at a first polishing speed and the second surface at a second polishing speed. 
     
     
       7. The method of  claim 1 , further comprising lapping the first surface prior to the operation of bonding. 
     
     
       8. A method for co-finishing surfaces, comprising:
 adhesively bonding a sapphire window to a zirconia structure such that a combined surface formed by a first surface of the sapphire window and a second surface of the zirconia structure is uneven; 
 placing a fill material in a gap between the sapphire window and the zirconia structure; and 
 co-finishing the sapphire window and the zirconia structure, thereby:
 removing a chamfered edge of the sapphire window; 
 making the combined surface even; and 
 conforming a first geometry of the first surface to a second geometry of the second surface. 
 
 
     
     
       9. The method of  claim 8 , wherein the first geometry of the first surface is flat and the second geometry of the second surface is curved. 
     
     
       10. The method of  claim 8 , wherein the fill material absorbs side force during the operation of co-finishing. 
     
     
       11. The method of  claim 8 , wherein the sapphire window has an additional chamfered edge that is removed by the operation of co-finishing. 
     
     
       12. The method of  claim 8 , wherein the sapphire window is transparent after the operation of co-finishing. 
     
     
       13. The method of  claim 8 , wherein the operation of co-finishing includes grinding the first surface and the second surface. 
     
     
       14. A method for co-finishing surfaces, comprising:
 providing a first material having a first surface with an aperture defined therein; 
 attaching, to the first material and in the aperture, a second material having a second surface and a chamfered edge adjacent the second surface, the second material positioned relative to the first material such that the first and second surfaces are non-contiguous; and 
 co-finishing the first material and the second material to make the first and second surfaces contiguous and to remove the chamfered edge; wherein 
 at least one of the first and second surfaces is non-planar. 
 
     
     
       15. The method of  claim 14 , wherein the second material is attached to the first material such that the second surface is proud of the first surface prior to co-finishing. 
     
     
       16. The method of  claim 14 , wherein the second material is attached to the first material such that the first surface is proud of the second surface prior to co-finishing. 
     
     
       17. The method of  claim 14 , wherein the first material and the second material are brittle. 
     
     
       18. The method of  claim 14 , wherein the operation of attaching the second material to the first material includes bonding the second material to the first material using a heat activated film, a two part adhesive, or an adhesive. 
     
     
       19. The method of  claim 14 , wherein the first material is reflective after the operation of co-finishing and the second material is translucent after the operation of co-finishing. 
     
     
       20. The method of  claim 14 , further comprising placing an epoxy fill between the second surface and the first surface perpendicular to a direction of the co-finishing.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a nonprovisional patent application of and claims the benefit of U.S. Provisional Patent Application No. 62/129,714, filed Mar. 6, 2015 and titled “Co-Finishing Surfaces,” the disclosure of which is hereby incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     This disclosure relates generally to processing of compound surfaces, and more specifically to co-finishing compound surfaces formed of brittle materials to form uniform surfaces. 
     BACKGROUND 
     Surfaces may be manufactured for a variety of different products, such as electronic devices. Such surfaces may be manufactured to have a variety of different properties depending on how the surface is intended to be used and/or the product into which the surface may be incorporated. 
     In some cases, such a surface may be formed of a single structure. In other cases, such a surface may be a compound surface formed by attaching multiple structures together. In cases where surfaces are compound, attachment of the multiple structures may result in an uneven surface. 
     SUMMARY 
     The present disclosure discloses systems and methods for co-finishing surfaces. A first structure with a first surface may be attached in an aperture defined in a second structure with a second surface such that there is an offset between the first and second surfaces. The first and second surfaces may be co-lapped and co-polished (and/or otherwise co-finished) to reduce and/or eliminate the offset. In this way, a more homogeneous compound surface may be formed while allowing for variations in thicknesses of the structures during attachment. 
     In various embodiments, a method for co-finishing surfaces may include: bonding a first structure formed of a first material and having a first surface in an aperture defined in a second structure formed of a second material and having a second surface such that there is an offset between the first surface and the second surface; co-lapping the first surface and the second surface to reduce the offset; and co-polishing the first surface and the second surface such that the first surface and the second surface are flush. 
     In some embodiments, a method for co-finishing surfaces may include: rough grinding a first surface of a first material, the first surface having an aperture defined therein; attaching a second material having a second surface to the aperture such that either the second surface is proud of the first surface by an offset or the first surface is proud of the second surface by the offset; and co-finishing the first surface and the second surface to reduce the offset. 
     In one or more embodiments, a method for co-finishing surfaces may include: adhesively bonding a sapphire window to a zirconia structure such that a combined surface formed by a first surface of the sapphire window and a second surface of the zirconia structure is uneven; placing a fill material in a gap between the sapphire window and the zirconia structure; and co-finishing the first surface and the second surface to make the combined surface even and to make a first geometry of the first surface conform to a second geometry of the second surface. 
     It is to be understood that both the foregoing general description and the following detailed description are for purposes of example and explanation and do not necessarily limit the present disclosure. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate subject matter of the disclosure. Together, the descriptions and the drawings serve to explain the principles of the disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-1H  illustrate components at multiple example stages of an example process for co-finishing surfaces. 
         FIG. 2  is a method diagram illustrating an example method for co-finishing surfaces. This example method may form the co-finished compound surface illustrated in  FIG. 1H . 
         FIGS. 3A-3B  illustrate a first alternative embodiment of components at multiple example stages of an example process for co-finishing surfaces. 
         FIGS. 4A-4B  illustrate a second alternative embodiment of components at multiple example stages of an example process for co-finishing surfaces. 
         FIG. 5  is a schematic diagram illustrating a manufacturing system for co-finishing surfaces. The system may perform the example method of  FIG. 2  and/or form the co-finished compound surface illustrated in  FIG. 1H . 
     
    
    
     DETAILED DESCRIPTION 
     The description that follows includes sample systems, methods, and apparatuses that embody various elements of the present disclosure. However, it should be understood that the described disclosure may be practiced in a variety of forms in addition to those described herein. 
     A compound surface may be formed by attaching or otherwise bonding two or more structures together. Such a process may result in an offset between respective surfaces of the structures due to manufacturing tolerance relating to the thicknesses of the structures, forming a non-uniform and non-contiguous compound surface. This may be exacerbated when an adhesive or other bonding structure is used, which may contribute to the offset because of the thickness of the adhesive. Attempting to increase manufacturing tolerance related to thicknesses by using less adhesive may decrease bonding strength. Conversely, attempting to increase bonding strength by using more adhesive may decrease manufacturing tolerance related to thicknesses. 
     An offset between the surfaces may cause a number of problems. As one surface may be proud of (or project from) the other, the edges of the proud surface may be more vulnerable to impact (such as if dropped onto a surface), especially if formed of a brittle material. Such an impact may fracture and/or otherwise damage one or more portions of the compound surface. Further, such an offset may cause light to reflect non-uniformly. Additionally, the offset may also be aesthetically unappealing, particularly if the positioned adjacent to the skin of a user, and may be perceived as lower quality manufacturing than if the compound surface was homogeneous. 
     The present disclosure relates to co-finishing surfaces. A first structure may be bonded (such as using heat activated film) or otherwise attached in an aperture defined in a second structure such that a first surface of the first structure is offset from (e.g., proud of) a second surface of the second structure. The first and second surfaces may be co-finished (such as by co-lapping and/or co-polishing) to reduce and/or eliminate the offset, rendering the first and second surfaces flush or more flush. In this way, a homogeneous (e.g., uniform and contiguous) compound surface may be formed while allowing greater tolerances between thicknesses of the attached structures and/or allowing the structures to be attached with high bonding strength. 
     In various implementations, techniques may be used that may prevent damage during co-finishing. For example, edges of one or more of the surfaces may be chamfered to mitigate fracturing during co-finishing. By way of another example, gaps between the first and second structures may be filled with a material such as heat cured epoxy fill that resists movement of the structures with respect to each other. Such a fill material may also form a seal resisting the passage of contaminants (such as water, dirt, and/or particles or substances used in co-finishing). 
     The first and second structures may be formed of different materials, which may be brittle materials. In some implementations, one of the structures may be formed of a material such as zirconia whereas the other structure is formed of a material such as glass, chemically strengthened glass, alumina, or sapphire. Either structure may be formed from any of the foregoing materials. 
     In some implementations, co-finishing may be performed differently on the first and second surfaces, such as at different speeds and/or for different amounts of time. For example, co-finishing may render one of the surfaces clear while rendering the other reflective. By way of another example, the surfaces may have different shapes or geometries prior to co-finishing (such as flat and curved) and co-finishing may alter the shape or geometry of one of the surfaces to more closely conform to the shape or geometry of the other. 
       FIGS. 1A-1H  illustrate components at multiple example stages of an example process for co-finishing surfaces.  FIG. 1A  shows a top plan view of a first structure  101 . The first structure  101  may be formed of a brittle material such as zirconia and/or other such material (such as glass, chemically strengthened glass, alumina, sapphire, and so on) and may be configured as a dome having a curved shape. In other embodiments the first structure may have a different shape; it may be non-planar, for example. It my define a complex curve. It may be conical. It may be elliptical or otherwise rounded, frustoconical, a planar geometric shape such as a trapezoid, square, truncated pyramid, and so on. As illustrated, the first structure  101  may define an aperture  103  into which a second structure  102  (see  FIG. 1H ) may be bonded and/or otherwise attached. The second structure  102  may be bonded in the aperture  103  to form a window in the first structure  101 . As also illustrated, an area of the first structure  101  around the aperture  103  may be configured as a shelf  113  to which the second structure  102  may be attached. 
     In various implementations, the combined assembly of the first structure  101  and the second structure  102  may form a portion of a housing of an electronic device (such as a smart phone, a mobile computing device, a tablet computing device, a desktop computer, a laptop computer, a wearable device, a display, a digital media player, and so on) and/or other apparatus. In such an implementation, the second structure  102  may function as a window through which one or more sensors and/or other devices may transmit and/or receive light, radio signals and/or other wireless transmissions, and so on. 
       FIG. 1B  illustrates a side cross sectional view of the first structure  101 , taken alone line A-A of  FIG. 1A . As illustrated, the first structure has a first surface  110 . As also illustrated, the first structure has sides  111  and a shelf  113  that define the aperture  103 . 
     The first structure  101  may be subjected to one or more processing operations. Such processing operations may remove material from the first surface  110 , make the first surface  110  more reflective, and/or otherwise alter the first surface  110 . For example, the first surface  110  may be subjected to one or more rough grinding and/or other grinding operations (an abrasive machining process where material of a surface is removed using a grinding tool that includes an abrasive surface such as diamond and/or other abrasive material). 
       FIG. 1C  shows an example of the first structure  101  of  FIG. 1B  after a rough grinding process has been performed on the first surface  110 . As illustrated, the thickness of the first structure  101  has been reduced by removing a portion of the first surface  110 . By way of example, the rough grinding process may have removed approximately 100-150 microns of the first surface  110 . 
       FIG. 1D  illustrates the first structure  101  of  FIG. 1C  after a second structure  102  has been bonded and/or otherwise attached in the aperture  103 . The second structure  102  may be formed of a brittle material such as glass, chemically strengthened glass, zirconia, alumina, sapphire, and/or other such material. The second structure  102  may be formed of a different material than the first structure  101  such that the first structure  101  is formed of a first material and the second structure  102  is formed of a second material. The second structure  102  may have a second surface  114  that may be configured with a different shape or geometry than the first surface  110  in certain embodiments, although in other embodiments the two may have similar or identical shapes. As illustrated, the second surface  114  is flat and the first surface  110  is curved, although the second structure may be convex, concave, a complex curve, conical, elliptical, or otherwise non-planar, as well as forming any suitable or desired geometric shape (e.g., a trapezoid, a truncated pyramid, a frustoconical shape, and so on). 
     The second structure  102  may be adhesively bonded in the aperture  103 . As illustrated, the second structure  102  may be adhesively bonded to the shelf  113  using an adhesive  116 . In some implementations, the adhesive  116  may be a heat activated film (HAF) that adhesively bonds the second structure  102  and the shelf  113  when the HAF is pressured between the second structure  102  and shelf  113  while the HAF is heated. In other implementations, the adhesive  116  may be any other kind of adhesive such as a one part adhesive, a two part adhesive, and so on. 
     As illustrated, the compound surface formed by the first surface  110  and the second surface  114  may not be uniform and contiguous. Instead, the positions of the first surface  110  and the second surface  114  differ by an offset  104 . Such an offset  104  between the first and second surfaces  110  and  114  may cause a number of problems. As the second surface  114  may be proud of (or project from) the first surface  110 , the edges of the second surface  114  may be more vulnerable to impact (such as if dropped onto a surface) than the rest of the second surface  114 , especially if the second structure  102  is formed of a brittle material. Such an impact may fracture and/or otherwise damage one or more portions of the second structure  102  and/or the second surface  114 . 
     Further, the offset  104  between the first and second surfaces  110  and  114  may cause light to reflect non-uniformly. The offset  104  may also be aesthetically unappealing, particularly if the compound surface formed by the first and second surfaces  110  and  114  is positioned adjacent to the skin of a user, and may be perceived as lower quality manufacturing than if the compound surface was homogeneous. 
     However, forming a uniform and contiguous compound surface by bonding the first and second structures  101  and  102  may be difficult. Forming a uniform and contiguous compound surface when bonding the first and second structures  101  and  102  may allow little manufacturing tolerance between the thicknesses of the first and second structures  101  and  102  in order to precisely match the first and second surfaces  110  and  114  without an offset  104 . This may be exacerbated by the adhesive  116 , which may contribute to the offset  104  because of the thickness of the adhesive  116 . Attempting to increase manufacturing tolerance between the thicknesses of the first and second structures  101  and  102  in order to precisely match the first and second surfaces  110  and  114  by using less adhesive  116  may decrease bonding strength between the first and second structures  101  and  102 . Conversely, attempting to increase bonding strength between the first and second structures  101  and  102  by using more adhesive  116  may decrease manufacturing tolerance between the thicknesses of the first and second structures  101  and  102 , making precise matching of the first and second surfaces  110  and  114  increasingly dependent on the exact thicknesses of the first and second structures  101  and  102 . 
     As such, the first and second surfaces  110  and  114  may be co-finished using one or more processes such as lapping (an abrasive machining process, less abrasive than grinding, where material is removed from a surface by rubbing abrasive materials between the surface and a lap tool) or polishing (an abrasive process, less abrasive than lapping, where a surface is smoothed by rubbing the surface with a polishing tool and/or exposing the surface to a chemical action) after the first and second surfaces  110  and  114  are attached. Such co-finishing may reduce or eliminate the offset  104  while allowing for greater manufacturing tolerances between the thicknesses of the first and second structures  101  and  102  without decreasing bonding strength. 
     Such co-finishing processes may subject the second structure  102 , the second surface  114 , the adhesive  116 , and so on to various stresses. One or more various techniques may be utilized to minimize damage from such co-finishing processes to the second structure  102 , the second surface  114 , the adhesive  116 , and so on. 
     For example, the rough grinding or grinding process described above as performed on the first surface  110  prior to attachment of the second structure  102  may be rougher than a process such as lapping or polishing. As such, the rough grinding or grinding process (and/or other processes such as lapping, polishing, and so on) may be performed on the first surface  110  prior to attachment as described above in order to prevent damage to the second structure  102 , the second surface  114 , the adhesive  116 , and so on. Additionally, various processes such as rough grinding, grinding, lapping, polishing and so on may be performed on the second structure  102  prior to attachment. 
     Further, edges of the second surface  114  may be more vulnerable to damage from such co-finishing processes than the rest of the second surface  114 . As illustrated, the second surface  114  may be configured with chamfered edges  118  in some implementations to reduce the possibility of fracturing and/or otherwise damaging the second surface  114  and/or other portions of the second structure  102  from co-finishing. 
     Additionally, gaps  117  between the second structure  102  and the sides  111  of the first structure  101  bordering the aperture may be filled with one or more different materials. For example, as shown in  FIG. 1F , fill material  115  such as heat cured epoxy or other fill material  115  may be positioned in the gaps  117 . Such a fill material  115  may form a cushion between the first structure  101  and the second structure  102 . Such a fill material  115  (which may be positioned perpendicular to the direction of one or more co-finishing operations) may also absorb side forces between the first structure  101  and the second structure  102  during one or more co-finishing processes, resisting movement of the second structure  102  with respect to the first structure  101 , preventing damage to the bond of the adhesive  116  and/or other damage from the co-finishing. 
     Further, the fill material  115  may form a seal between the first and second structures  101  and  102 . Such a seal may form an environmental barrier resisting passage of water, air, dirt, and/or other contaminants through the gaps  117 . Such a seal may also resist passage of grit, polishing compounds, and/or other particles through the gaps  117  that may be utilized in one or more co-finishing processes. 
     As illustrated in  FIG. 1E , in various implementations the fill material  115  in the form of liquid beads may be placed on the gaps  117  of the bonded first and second structures  101  and  102  of  FIG. 1D . As shown in  FIG. 1F , the fill material  115  may then wick into the gaps  117 , filling the gaps  117 . 
       FIG. 1G  illustrates an example of the first and second structures  101  and  102  of  1 F after a co-lapping process is performed on the first and second surfaces  110  and  114 . Such a co-lapping process may remove a portion of the first and second surfaces  110  and  114 . However, as the co-lapping process may be less rough than the rough grinding or grinding process discussed above, less material may be removed from the first surface  110  by the co-lapping process than the rough grinding or grinding process discussed above. For example, the co-lapping process may have removed approximately 60 to 90 microns of material from the first surface  110  and/or from the second surface  114 , though the co-lapping process may remove different amounts of material from the first surface  110  and the second surface  114 . As illustrated, this may result in a reduction of the offset  104 . As also illustrated, the co-lapping process may have removed the chamfered edges  118 . 
     As illustrated, in some embodiments the co-lapping process may also alter the geometry of the second surface  114 . The alteration may make the geometry of the second surface  114  more closely match the geometry of the first surface  110 . For example, the flat geometry of the second surface  114  prior to co-lapping may be rendered more curved like the curved geometry of the first surface  110  after co-lapping. 
       FIG. 1H  illustrates an example of the first and second structures  101  and  102  of  1 G after a co-polishing process is performed on the first and second surfaces  110  and  114 . Such a co-polishing process may remove a portion of the first and second surfaces  110  and  114 . However, as the co-polishing process may be less rough than the co-lapping process discussed above, less material may be removed from the first and second surfaces  110  and  114  by the co-polishing process than the co-lapping process discussed above. For example, the co-lapping process may have removed approximately 10 to 20 microns of material from the first surface  110  and/or from the second surface  114 , though the co-polishing process may remove different amounts of material from the first surface  110  and the second surface  114 . As illustrated, this may result in a homogenous (contiguous and uniform) compound surface formed of the first and second surfaces  110  and  114  by eliminating the offset  104 . 
     As illustrated, in some embodiments the co-polishing process may also alter the geometry of the second surface  114 . The alteration may make the geometry of the second surface  114  more closely match the geometry of the first surface  110 . For example, the geometry of the second surface  114  prior to co-polishing may be rendered even more curved like the curved geometry of the first surface  110  after co-polishing. 
     Although the discussion above describes both co-lapping and co-polishing as altering the geometry of the second surface  114 , it is understood that this is an example. In various implementations, such alteration may be performed by one or more of the processes without being performed by both without departing from the scope of the present disclosure. In still other implementations, neither co-lapping nor co-polishing may alter the geometry of the second surface  114  without departing from the scope of the present disclosure, though various other co-finishing operations may be performed to alter such geometry. 
     Further, although the discussion above describes co-finishing the first and second surfaces  110  and  114  as including both co-lapping and co-polishing, it is understood that this is an example. In various implementations, such co-finishing may omit one or more of these processes and/or may include one or more other processes such as grinding without departing from the scope of the present disclosure. 
     Although co-finishing processes such as co-lapping and co-polishing are described above as being performed on both the first surface  110  and the second surface  114 , such co-finishing processes may not be performed identically on the first surface  110  and the second surface  114 . The first and second surfaces  110  and  114  may be finished at different finishing speeds, utilizing different finishing tools, and/or at different times during at least part of one or more co-finishing processes without departing from the scope of the present disclosure. 
     For example, a co-lapping process may be performed by positioning a lap tool such that the lap tool laps the second surface  114  until sufficient material is removed from the second surface  114  that the lap tool laps both the first and second surfaces  110  and  114 . In such an example, the lapping may be performed at a first speed when only the second surface  114  is being lapped and at a second speed when both the first and second surfaces  110  and  114  are being lapped. This may result in the first surface  110  being configured to be reflective while the second surface  114  is configured to be translucent, transparent, or clear due to the different lapping times and/or lapping speeds and/or other finishing variations. 
     By way of another example, a polishing process may be performed that first polishes part of the first surface  110 , then the second surface  114 , and then another part of the first surface  110 . Such polishing may polish the first and second surfaces  110  and  114  at different speeds, for different amounts of time, and so on. This variation may result in the first surface  110  being configured to be reflective while the second surface  114  is configured to be translucent, transparent, or clear and/or other finishing variations. 
     By way of still another example, a co-finishing process may be performed on the first and second surfaces  110  and  114  using a finishing tool that has multiple finishing surfaces. The multiple finishing surfaces may be capable of operating at different finishing speeds from other of the multiple finishing surfaces such that the first surface  110  may be finished by one of the finishing surfaces at a first speed while the second surface  114  may be finished by another of the finishing surfaces at a second speed. These different finishing speeds may result in the first surface  110  being configured to be reflective while the second surface  114  is configured to be translucent, transparent, or clear and/or other finishing variations. 
       FIG. 2  is a method diagram illustrating an example method  200  for co-finishing surfaces. This example method  200  may form the co-finished compound surface illustrated in  FIG. 1H . 
     The flow may begin at block  201  where a rough grind operation may be performed on a first surface of a first material. The flow may then proceed to block  202  where edges of a second surface of a second material may be chamfered. Next, the flow may proceed to block  203  where the second surface of the second material may be lapped. 
     The flow may then proceed to block  204  where the second material may be attached in an aperture of the first material. Attachment of the second material to the first material may result in the second surface being positioned proud of the first surface. Subsequently, the flow may proceed to block  205  where gaps between the first and second materials may be filled. The flow may then proceed to block  206 . 
     At block  206 , the first and second surfaces may be co-lapped. The co-lapping may alter a shape or geometry of the second surface. The co-lapping may also alter (such as by reducing or eliminating) an offset between the first and second surfaces. The flow may then proceed to block  207  where the first and second surfaces may be co-polished. The co-polishing may also alter a shape or geometry of the second surface and/or alter an offset between the first and second surfaces. 
     Although the example method  200  is illustrated and described as including particular operations performed in a particular order, it is understood that this is an example. In various implementations, various orders of the same, similar, and/or different operations may be performed without departing from the scope of the present disclosure. 
     For example, in various implementations operations such as those illustrated at blocks  201 ,  202 , and/or  203  may be omitted. By way of another example, the example method  200  is illustrated and described as co-lapping followed by co-polishing. However, in various implementations various co-finishing operations may be performed that may or may not include co-lapping, co-polishing, and/or other co-finishing processes without departing from the scope of the present disclosure. 
     Returning to  FIG. 1H , although a particular compound assembly formed by particularly configured first and second structures  101  and  102  is shown, it is understood that this is an example. Other compound assemblies formed of differently configured first and/or second structures  101  and  102  are possible and contemplated without departing from the scope of the present disclosure. 
     For example, the first structure is shown as configured with a concave shape or geometry. However,  FIGS. 3A-3B  illustrate a first alternative embodiment of components at multiple example stages of an example process for co-finishing surfaces where first structure or material  301  is configured with a flat shape or geometry ( FIG. 3A  showing compound assembly formed by attaching a second structure or material  302  to the first structure or material  301  and  FIG. 3B  showing the compound assembly of  FIG. 3A  after performance of one or more co-finishing processes). Further,  FIGS. 4A-4B  illustrate a second alternative embodiment of components at multiple example stages of an example process for co-finishing surfaces where first structure or material  401  is configured with a convex shape or geometry ( FIG. 4A  showing compound assembly formed by attaching a second structure or material  402  to the first structure or material  401  and  FIG. 4B  showing the compound assembly of  FIG. 4A  after performance of one or more co-finishing processes). 
     Additionally, although  FIG. 1H  illustrates the second surface  114  as flush with the first surface  110  after co-finishing, it is understood that this is an example. In various implementations, after co-finishing the second surface  114  may remain proud (though the offset  104  may be reduced) of the first surface  110  (such as in  FIG. 4B ) and/or the first surface  110  may be proud of the second surface  114  (such as in  FIG. 3B  where the offset  304  becomes a reverse offset) without departing from the scope of the present disclosure. 
     Moreover, although  FIG. 1H  illustrates the aperture  103  as extending through the first structure  101 , it is understood that this is an example. In various implementations, such as in  FIG. 3B , the aperture  103  may extend only partially into the first structure  101  such that a cavity is formed into which the second structure  102  may be attached. 
     Further, although  FIG. 1H  is illustrated and described as attaching the second structure  102  in an aperture  103  of the first structure  101 , it is understood that this is an example and that other configurations are possible and contemplated without departing from the scope of the present disclosure. For example, in some implementations two or more structures may be attached side by side without one being attached in an aperture defined in the other. 
       FIG. 5  is a schematic diagram illustrating a manufacturing system  500  for co-finishing surfaces. The system  500  may perform the example method  200  of  FIG. 2  and/or form the co-finished compound surface illustrated in  FIG. 1H . 
     As illustrated, the system  500  may include a controller  501  communicably connected to a movement apparatus  502  (such as a conveyor belt) and a number of stations  503 - 506 . As illustrated, the stations  503 - 506  may include a bonding station  503 , a fill station  504 , a co-lapping station  505 , and a co-polishing station  506 . 
     The controller  501  may include components not shown (such as one or more processing units, one or more communication components, one or more non-transitory storage media [which may take the form of, but is not limited to, a magnetic storage medium; optical storage medium; magneto-optical storage medium; read only memory; random access memory; erasable programmable memory; flash memory; and so on] and so on. The controller  501  may signal the movement apparatus  502  to move the first structure  101  in a direction  507  between the stations  503 - 506  and signal the stations  503 - 506  to perform various operations on the first structure  101 . 
     For example, the controller  501  may signal the movement apparatus  502  to move the first structure  101  to the bonding station  503  and signal the bonding station  503  to bond the second structure  102  to the first structure. The controller  501  may then signal the movement apparatus  502  to move the bonded first and second structures  101  and  102  to the fill station  504  and signal the fill station  504  to fill the gaps  117  between the first and second structures  101  and  102 . Next, the controller  501  may signal the movement apparatus  502  to move the filled first and second structures  101  and  102  to the co-lapping station  505  and signal the co-lapping station  505  to co-lap the first and second surfaces  110  and  114  of the first and second structures  101  and  102 . The controller  501  may then signal the movement apparatus  502  to move the co-lapped first and second structures  101  and  102  to the co-polishing station  506  and signal the co-polishing station  506  to co-polish the first and second surfaces  110  and  114  of the first and second structures  101  and  102 . 
     As described above and illustrated in the accompanying figures, the present disclosure relates to co-finishing surfaces. A first structure may be bonded (such as using heat activated film) or otherwise attached in an aperture defined in a second structure such that a first surface of the first structure is offset from (e.g., proud of) a second surface of the second structure. The first and second surfaces may be co-finished (such as by co-lapping and/or co-polishing) to reduce and/or eliminate the offset, rendering the first and second surfaces flush or more flush. In this way, a homogeneous (e.g., uniform and contiguous) compound surface may be formed while allowing greater tolerances between thicknesses of the attached structures and/or allowing the structures to be attached with high bonding strength. 
     In the present disclosure, the methods disclosed may be implemented as sets of instructions or software readable by a device. Further, it is understood that the specific order or hierarchy of steps in the methods disclosed are examples of sample approaches. In other embodiments, the specific order or hierarchy of steps in the method can be rearranged while remaining within the disclosed subject matter. The accompanying method claims present elements of the various steps in a sample order, and are not necessarily meant to be limited to the specific order or hierarchy presented. 
     The described disclosure may utilize a computer program product, or software, that may include a non-transitory machine-readable medium having stored thereon instructions, which may be used to program a computer system (such as a computer controlled manufacturing system or other electronic device) to perform a process according to the present disclosure. A non-transitory machine-readable medium includes any mechanism for storing information in a form (e.g., software, processing application) readable by a machine (e.g., a computer). The non-transitory machine-readable medium may take the form of, but is not limited to, a magnetic storage medium (e.g., floppy diskette, video cassette, and so on); optical storage medium (e.g., CD-ROM); magneto-optical storage medium; read only memory (ROM); random access memory (RAM); erasable programmable memory (e.g., EPROM and EEPROM); flash memory; and so on. 
     It is believed that the present disclosure and many of its attendant advantages will be understood by the foregoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components without departing from the disclosed subject matter or without sacrificing all of its material advantages. The form described is merely explanatory, and it is the intention of the following claims to encompass and include such changes. 
     While the present disclosure has been described with reference to various embodiments, it will be understood that these embodiments are illustrative and that the scope of the disclosure is not limited to them. Many variations, modifications, additions, and improvements are possible. More generally, embodiments in accordance with the present disclosure have been described in the context or particular embodiments. Functionality may be separated or combined in blocks differently in various embodiments of the disclosure or described with different terminology. These and other variations, modifications, additions, and improvements may fall within the scope of the disclosure as defined in the claims that follow.

Metadata:
Filing Date: 20150518
Publication Date: 20190219
Grant Date: 20190219
Priority Date: 20150306
Inventors: MATSUYUKI, NAOTO
YI, Bin
QU, DEZHENG
MANJUNATHAIAH, JAIRAM
NATHANSON, SCOTT M.
NESS, TREVOR J.
NAZZARO, DAVID I.
MOLINA, RAUL A.
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C70/745", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/88", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24B37/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24B37/042", "inventive": true, "first": true, "tree": "[]"}, {"code": "B24B37/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "C03C25/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24B37/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24B37/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24B1/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "F16B11/006", "inventive": false, "first": false, "tree": "[]"}, {"code": "B24B37/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24B37/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "F16B11/006", "inventive": false, "first": false, "tree": "[]"}, {"code": "B24B37/042", "inventive": true, "first": true, "tree": "[]"}, {"code": "C03C25/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/745", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/88", "inventive": true, "first": false, "tree": "[]"}, {"code": "B24B37/042", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 56849540