PATENT DOCUMENT

Publication Number: US-10873125-B2
Application Number: US-201916565033-A
Country: US
Kind Code: B2

Title: Two-shot knuckles for coupling electrically isolated sections of an electronic device and methods for making the same

Abstract:
Two shot knuckles include a first shot component and a second shot component. Both shot components are composed of different dielectric materials, where the first shot is composed of a relatively high strength structural material and the second is composed of a cosmetic material. The first shot component can physically couple two conductive sections together by interfacing with a coupling structure of that section. The first shot component includes second shot retaining regions and a cosmetic region. The second shot component occupies the cosmetic region and anchors itself to the first shot component using the second shot retaining regions. The second shot may be the only part of the two-shot knuckle visible to a user of an electronic device and can exhibit any desired color.

Claims:
What is claimed is: 
     
       1. An enclosure for a portable electronic device, the enclosure comprising:
 a first section formed from a first conductive material and defining a first portion of an exterior sidewall of the enclosure; 
 a second section formed from a second conductive material and defining a second portion of the exterior sidewall of the enclosure; and 
 a composite intermediate section positioned at least partially between the first section and the second section, the composite intermediate section comprising:
 a first shot formed from a first dielectric material comprising a first polymer and a fiber, the first shot bonding the first section to the second section; and 
 a second shot formed from a second dielectric material comprising a second polymer that defines a third portion of the exterior sidewall of the enclosure. 
 
 
     
     
       2. The enclosure of  claim 1 , wherein:
 the first section defines a top of the enclosure; 
 the second section defines a first portion of a side of the enclosure; and 
 
       the second shot of the composite intermediate section defines a second portion of the side of the enclosure. 
     
     
       3. The enclosure of  claim 2 , wherein:
 the enclosure further comprises a third section formed from a third conductive material; 
 the composite intermediate section is a first composite intermediate section; and 
 the enclosure further comprises a second composite intermediate section positioned at least partially between the first section and the third section. 
 
     
     
       4. The enclosure of  claim 1 , wherein:
 the first section defines a first coupling feature along an interior of the enclosure; 
 the second section defines a second coupling feature along the interior of the enclosure; and 
 the first shot bonds the first section to the second section by at least partially encapsulating the first coupling feature and the second coupling feature. 
 
     
     
       5. The enclosure of  claim 1 , wherein:
 the first polymer is a nylon material; and 
 the fiber is a glass fiber that is embedded in the nylon material. 
 
     
     
       6. The enclosure of  claim 1 , wherein the first conductive material and the second conductive material are a steel material. 
     
     
       7. The enclosure of  claim 1 , wherein the first conductive material and the second conductive material are an aluminum material. 
     
     
       8. An electronic device comprising:
 electronic circuitry; and 
 an enclosure at least partially surrounding the electronic circuitry and comprising:
 a first conductive section defining a first portion of an exterior surface of the enclosure and electrically coupled to the electronic circuitry; 
 a second conductive section defining a second portion of the exterior surface of the enclosure and separated from the first conductive section by a gap; 
 a first dielectric section comprising a first polymer, the first dielectric section structurally coupling the first conductive section to the second conductive section; and 
 a second dielectric section comprising a second polymer positioned at least partially within the gap and defining a third portion of the exterior surface of the enclosure. 
 
 
     
     
       9. The electronic device of  claim 8 , wherein:
 the first dielectric section defines a coupling feature; and 
 the second dielectric section is molded around the coupling feature thereby structurally coupling the second dielectric section to the first dielectric section. 
 
     
     
       10. The electronic device of  claim 8 , wherein the first dielectric section comprises a glass fiber embedded within the first polymer. 
     
     
       11. The electronic device of  claim 8 , wherein:
 the first conductive section is formed from a metal material that is electrically coupled to the electronic circuitry; and 
 the first conductive section is configured to operate as an antenna for the electronic device. 
 
     
     
       12. The electronic device of  claim 8 , wherein:
 the first conductive section comprises a first coupling feature; 
 the second conductive section comprises a second coupling feature; and 
 the first dielectric section is molded over the first and second coupling features to structurally couple the first conductive section to the second conductive section. 
 
     
     
       13. The electronic device of  claim 12 , wherein:
 the first coupling feature includes a first protrusion that extends into an interior region of the enclosure; 
 the second coupling feature includes a second protrusion that extends into the interior region of the enclosure; and 
 the first polymer at least partially encapsulates the first protrusion and the second protrusion. 
 
     
     
       14. The electronic device of  claim 13 , wherein:
 the first protrusion defines a first recess; 
 the second protrusion defines a second recess; and 
 the first polymer at least partially fills the first recess and the second recess. 
 
     
     
       15. An enclosure for a portable electronic device, the enclosure comprising:
 a first section formed from a first conductive material and defining at least a portion of a top exterior surface of the enclosure; 
 a second section formed from a second conductive material and defining at least a portion of a side exterior surface of the enclosure and separated from the first section by a gap; and 
 a composite intermediate section positioned at least partially within the gap and comprising:
 a first shot comprising a first polymer and a fiber, the first shot mechanically coupling the first section to the second section; and 
 a second shot comprising a second polymer that is mechanically coupled to the first shot and defines a portion of an exterior surface of the enclosure. 
 
 
     
     
       16. The enclosure of  claim 15 , wherein:
 the side exterior surface is a first side exterior surface; 
 the enclosure further comprises a third section formed from a third conductive material and defines a second side exterior surface that is opposite to the first side exterior surface; 
 the composite intermediate section is a first composite intermediate section; and 
 the enclosure further comprises a second composite intermediate section that is positioned between the first section and the third section. 
 
     
     
       17. The enclosure of  claim 15 , wherein:
 the first section defines a protruding coupling feature; and 
 the first shot at least partially encapsulates the protruding coupling feature. 
 
     
     
       18. The enclosure of  claim 15 , wherein:
 the first and second conductive materials are a steel or an aluminum material; and 
 the first section is configured to operate as an antenna of the portable electronic device. 
 
     
     
       19. The enclosure of  claim 15 , wherein the second shot is substantially free of fibers. 
     
     
       20. The enclosure of  claim 15 , wherein:
 the portion of the exterior surface of the enclosure defined by the second shot is an additional portion of the side exterior surface of the enclosure.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application is a continuation patent application of U.S. patent application Ser. No. 16/134,898, filed Sep. 18, 2018 and titled “Two-Shot Knuckles for Coupling Electrically Isolated Sections of an Electronic Device and Methods for Making the Same,” which is a continuation patent application of U.S. patent application Ser. No. 15/678,704, filed Aug. 16, 2017 and titled “Two-Shot Knuckles for Coupling Electrically Isolated Sections of an Electronic Device and Methods for Making the Same,” now U.S. Pat. No. 10,290,926, which is a continuation patent application of U.S. patent application Ser. No. 14/659,689, filed Mar. 17, 2015 and titled “Two-Shot Knuckles for Coupling Electrically Isolated Sections of an Electronic Device and Methods for Making the Same,” now U.S. Pat. No. 9,755,296, which is a continuation patent application of U.S. patent application Ser. No. 13/251,026, filed Sep. 30, 2011 and titled “Two-Shot Knuckles for Coupling Electrically Isolated Sections of an Electronic Device and Methods for Making the Same,” now U.S. Pat. No. 9,007,748, which claims the benefit of U.S. Provisional Patent Application No. 61/529,728, filed Aug. 31, 2011 and titled “Two-Shot Knuckles for Coupling Electrically Isolated Sections of an Electronic Device and Methods for Making the Same,” the disclosures of which are hereby incorporated herein by reference in their entireties. 
    
    
     FIELD 
     Systems and methods are disclosed for coupling sections of an electronic device. In particular, components of an electronic device can be assembled from two or more sections, where these sections may be coupled together using two-shot knuckles. 
     BACKGROUND 
     A portable electronic device can be constructed using different approaches. In some cases, an electronic device can be constructed by assembling several components together. These “components” can include external components that are combined to form a device enclosure (e.g., a device “housing”), as well as internal components that may provide structural support or other functionality for the electronic device (e.g., the internal component could be a microchip). Based on the design of the electronic device, the components can be formed from any suitable material(s) such as metals, plastics, or any other materials. 
     In some cases, the various components of the electronic device can operate as part of an electrical circuit. For example, a particular component could serve as a resistor or as a capacitor to another part of the electronic device. As another example, a component can function as part of an antenna assembly of the electronic device. If the component is used in only a single electrical circuit, then the component may be constructed from a single piece of conductive material. If the same component, however, is used in several different electrical circuits, the component may need to be constructed from several “sections” of conductive elements. In this case, however, it may be necessary to separate each of the conductive sections with an insulating or other non-conductive material, in order to ensure that each section operates in its own electrical circuit correctly. In some cases, it may be desirable for this insulating material to exhibit desired cosmetic properties as well as perform its functional duties of coupling the sections together and electrically isolating them. 
     SUMMARY 
     Two-shot knuckles for coupling electrically isolated conductive sections of an electronic device and methods for making the same are provided. In some embodiments, an electronic device can be formed from several components, such as an outer periphery component and/or other components. The outer periphery component may provide a housing structure for the electronic device by encircling the electronic device. In some cases, this outer periphery component can be assembled from two or more “sections.” Knuckles may then be used to couple these sections together. 
     The shape and structure of the knuckles can be based on various design considerations. Two shot knuckles include a first shot component and a second shot component. Both shot components are composed of different dielectric materials, where the first shot is composed of a relatively high strength structural material and the second is composed of a cosmetic material. The first shot component can physically couple two conductive sections together by interfacing with a coupling structure of each section. The first shot component includes second shot retaining regions and a cosmetic region. The second shot component occupies the cosmetic region and anchors itself to the first shot component using the second shot retaining regions. The second shot may be the only part of the two-shot knuckle visible to a user of an electronic device and can exhibit any desired color. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the present invention, its nature and various advantages will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings in which: 
         FIG. 1  shows a schematic view of an illustrative component of an electronic device in accordance with some embodiments of the present invention; 
         FIGS. 2A-G  show several views of an illustrative bracket in accordance with some embodiments of the invention; 
         FIGS. 2H-2N  show several views of another illustrative bracket in accordance with some embodiments of the invention; 
         FIGS. 3A and 3B  show illustrative views of a bracket welded to a section in accordance with some embodiments of the invention; 
         FIG. 4  shows an illustrative view of another bracket welded to a section in accordance with some embodiments of the invention; 
         FIGS. 5A and 5B  show various views of a particular knuckle design in accordance with one embodiment of the invention; 
         FIGS. 6A-6C  show various schematic views of another particular knuckle design in accordance with one embodiment of the invention; 
         FIG. 7  shows a cross-sectional view of the knuckle of  FIG. 6A  in accordance with one embodiment of the invention; 
         FIGS. 8A-8C  show various schematic views of yet another particular knuckle design in accordance with one embodiment of the invention; 
         FIG. 9  shows a two-shot knuckle according to some embodiments of the invention; 
         FIG. 10  shows a cross-sectional view of the knuckle of  FIG. 9  taken along line A-A in accordance with an embodiment of the invention; 
         FIGS. 11A-B ,  12 A-B,  13 A-B, and  14 A-B show illustrative views of a series of process steps used to manufacture a two-shot knuckle in accordance with some embodiments of the invention; and 
         FIG. 15  shows an illustrative process for mechanically coupling two conductive sections together with a two-shot knuckle in accordance with some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     An electronic device can include several components assembled together to form internal and/or external features of the electronic device. For example, one or more internal components (e.g., electrical circuitry and/or internal support structures) can be placed within external components (e.g., housing structures) to provide an electronic device having desired functionality. As used herein, the term “component” refers to a distinct entity of an electronic device, such as a particular electronic circuit (e.g., a microchip), a member forming the housing of the electronic device (e.g., a backplate, an outer periphery component, and the like), an internal support structure (e.g., a mid-plate), and the like. 
     In some cases, a component can be manufactured by assembling and connecting two or more different individual elements (i.e., “sections”) together. As used herein, the term “section” refers to an individual portion of a component, where that component may be formed from multiple sections. The various sections of the component may then be coupled together using a “knuckle.” Based on the desired functionality and design of the component and its sections, these knuckles can exhibit a wide range of shapes and structures. For example, the knuckles can include structural designs that reinforce the knuckle at areas of high mechanical strain, that counteract twisting movements at areas of high torsion, that interlock two sections together such that they are mechanically coupled together, that provide electrical isolation between the sections, and the like. 
       FIG. 1  shows a schematic view of an illustrative component of an electronic device in accordance with some embodiments of the present invention. In particular,  FIG. 1  shows outer periphery component  100  that can be constructed by connecting several sections together, such as sections  110 ,  120 ,  130 , and  140 . Outer periphery component  100  can be constructed to form an exterior, periphery surface for an electronic device. In particular, outer periphery component  100  can surround or wrap around some or all of the internal components (e.g., electronic circuits, internal support structures, and the like) of the electronic device. In other words, outer periphery component can define an internal volume into which internal components can be placed. 
     The thickness, length, height, and cross-section of outer periphery component  100  can be selected based on any suitable criteria including, for example, based on structural requirements (e.g., stiffness or resistance to bending, compression, tension or torsion in particular orientations). In some embodiments, outer periphery component  100  can serve as a structural member to which other electronic device components can be mounted. Some of the structural integrity of outer periphery component  100  can come from the closed shape that it defines (e.g., outer periphery component  100  forms a loop, thus providing structural integrity). 
     Outer periphery component  100  can have any suitably shaped cross-section. For example, outer periphery component  100  can have a substantially rectangular cross-section. Each corner of the substantially rectangular cross-section can be rounded in shape, thus forming a “spline.” As used herein, the term “spline” refers to a rounded corner portion of an outer periphery component. In some embodiments, outer periphery component  100  can have a cross-section in any other suitable shape including, for example, a circular shape, an oval shape, a polygonal shape, or a curved shape. In some embodiments, the shape or size of the cross-section of outer periphery component  100  can vary along the length or width of the electronic device (e.g., an hourglass shaped cross-section). 
     Outer periphery component  100  of the electronic device can be constructed using any suitable process. In some embodiments, outer periphery component  100  can be constructed by connecting section  110  and section  120  together at interface  112 , connecting section  120  and section  130  together at interface  122 , connecting section  130  and section  140  together at interface  132 , and connecting section  140  and section  110  together at illustrated in  FIG. 1  as being constructed from four sections, one skilled in the art could appreciate that outer periphery component  100  could alternatively be formed from any suitable number of two or more sections, and that the interfaces between the sections may be positioned at any location on outer periphery component  100 . 
     Each section  110 ,  120 ,  130 , and  140  can be constructed individually and later assembled to form outer periphery component  100 . For example, each section can be individually constructed using one or more of stamping, machining, working, casting, or any combinations of these. In some embodiments, the materials selected for sections  110 ,  120 ,  130 , and  140  can be conductive, thus allowing the sections to provide an electrical functionality for the electronic device. For example, sections  110 ,  120 ,  130  and/or  140  can be formed from a conductive material such as stainless steel or aluminum. In some embodiments, each section may serve as an antenna for the electronic device. 
     To mechanically couple individual sections together, knuckles  114 ,  124 ,  134 , and  144  can exist at interfaces  112 ,  122 ,  132 , and  134  respectively. In some embodiments, each of the knuckles can be constructed from a material that can begin in a first state and may subsequently change to a second state. As an illustration, the knuckles can be constructed from a plastic that begins in a first, liquid state and then subsequently changes to a second, solid state. While in the liquid state, the plastic can be allowed to flow into interfaces  112 ,  122 ,  132 , and  142 . After flowing into these interfaces, the plastic material may subsequently be allowed to harden into knuckles  114 ,  124 ,  134 , and  144  (e.g., the plastic material is allowed to change into the second, solid state). Upon changing into the solid state, the plastic material may then bond together sections  110  and  120 ,  120  and  130 , and  140  and  110 , respectively, thus forming a single new component (e.g., outer periphery component  100 ). In one embodiment, knuckle  134  may be cosmetic and not physically couple sections  130  and  140  together. In this embodiment, sections  130  and  140  can be welded together so that they are physically and electrically coupled. In another embodiment, knuckle may physically couple sections  130  and  140  together in accordance with principles of the invention. 
     Knuckles  114 ,  124 , and  144  not only physically couple together sections  110  and  120 ,  120  and  130 , and  140  and  110 , respectively, they electrically isolate section  110  from section  120 , section  120  from section  130 , and section  140  from section  110 . For purposes of this discussion, assume sections  130  and  140  are electrically the same because they are welded together, and that knuckle  134  is cosmetic. As will be explained in more detail below, knuckles  114 ,  124 , and  144  encapsulate and/or exist with coupling structures that are attached to or integrally formed parts of sections  110 ,  120 ,  130 , and  140 . That is, when the knuckle in its first state (e.g., the liquid state), it flows into and/or around the coupling structures. A shutoff device (not shown) may be positioned at each interface to shape the knuckle for when it transforms into its second state (e.g., the solid state). As shown in  FIG. 1 , knuckles  114  and  124  are asymmetric in shape and knuckle  144  is symmetric in shape. 
     The coupling structures (not shown) exist on sections  110 ,  120 ,  130 , and  140 . Some sections (e.g., sections  110  and  120 ) may have two coupling structures whereas other sections (e.g., sections  130  and  140 ) have one coupling structure for interfacing with a knuckle. In some embodiments, the coupling structure can be a bracket such as that shown, for example, in  FIG. 2 . The bracket can be attached or welded to an inside surface of a section. In another embodiment, the coupling structure can be an integrally formed part of the section that was originally part of the section. In  FIG. 1 , knuckle  114  interfaces with a bracket and an integrally formed coupling structure and knuckles  124  and  144  interface with two brackets. 
     Any suitable process can be used to place the knuckle material into interfaces  112 ,  122 ,  132 , and  142 , and any suitable process can be used to change the knuckle material from the first state to the second state. In some embodiments, a “molding process” can be used in which the knuckle material is initially inserted in a liquid state and then is subsequently hardened. For example, one or more of injection molding, compression molding, transfer molding, extrusion molding, blow molding, thermoforming, vacuum forming, or rotomolding processes can be used. In this case, a “one shot” process can be used in which the knuckle material is inserted in a single step, and then independently changes to its second state. In other words, the knuckle can be formed in a single step (e.g., in “one shot”) without necessitating additional steps or manufacturing processes. 
     The knuckle material may be any material suitable for mechanically coupling two sections together and electrically isolate the two section. The knuckle material may be a plastic such as a thermal plastic. In one embodiment, the knuckle material may be a glass filled nylon. 
       FIGS. 2A-G  show several views of an illustrative bracket  200  in accordance with an embodiment of the invention that can be mounted to one of the sections. In particular,  FIGS. 2A-G  show back, top, front, left, right, bottom, and isometric views respectively of bracket  200 . Bracket  200  can include three legs  210 ,  220 , and  230 , which extend from planar member  240 . Legs  210  and  220  may both extend away from planar member  240  at a right angle (e.g., 90 degrees), whereas leg  230  may extend away from leg  230  at angle between 1 and 90 degrees. Leg  230  can have slot  232  to promote flow of knuckle material when it is in its first state. In addition, plate  240  can have through-hole  242  or a cutout of any suitable shape to promote flow of knuckle material when in its first state. Legs  210 ,  220 , and  230  may have feet  214 ,  224 , and  234 , respectively, for being welded to a surface of one of the sections. 
     Bracket  200  can be constructed from any suitable material. In some embodiments, bracket  200  is constructed from a conductive material such as metal (e.g., steel or aluminum). In some embodiments, bracket  200  is constructed from the same material as the section it is being welded to. For example, bracket  200  and the section it is being welded to can both be constructed from stainless steel. 
     It is understood that brackets of any suitable construction can be used in connection with the sections. For example,  FIGS. 2H-2N  shows several views of bracket  250  constructed in accordance with an embodiment of the invention. Bracket  250  is similar in many respects to bracket  200  as it includes legs and welding feet, as well as a cutout for promoting knuckle material flow. 
     Referring now to  FIGS. 3A and 3B , illustrative views of bracket  200  welded to section  300  are shown. In particular,  FIG. 3A  shows an illustrative cross-sectional view and  FIG. 3B  shows an illustrative top view. Bracket  200  is shown sitting within recess  310  of section  300 . Recess  310  may have been machined out of section  300  during or after manufacture of section  300 . Recess  310  may serve as a vessel for retaining a portion of a knuckle as it transitions from its first to second state. As shown, feet  214 ,  224 , and  234  are welded to recess  310 . This weld physically anchors bracket  200  to section  300  and electrically couples bracket to section  300 . 
     The edge of bracket  200  aligns with the edge of section  300 . This alignment may be a product of a cutting operation that physically cuts away a portion of bracket  200  and section  300 . It is the total cross-sectional area of the aligned edges of bracket  200  and section  300  that control capacitance of the knuckle coupling two sections together. Smaller cross-sections generally result in less capacitance. In embodiments where the section is used as an antenna, lower capacitance enhances antenna performance. The cross-sectional area can be varied, for example, by increasing the thickness of bracket  200  or using a bracket that has a different cross-sectional shape. See  FIG. 4  as an example of another bracket  400  having a different cross-sectional shape. 
       FIG. 5A  shows an illustrative enlarged perspective view of sections  110  and  140  (of  FIG. 1 ) having respective brackets  200  welded thereto in accordance with an embodiment of the invention.  FIG. 5A  also shows contact members  520  and  540  welded to top of the planer member of each bracket  200 . Contact members  520  and  540  have a cutout that mimics cutout  242  of bracket  200  and that promotes flow of knuckle material when it is in its first state. A portion of contact members  520  and  540  will be left exposed after the knuckle material encapsulates brackets  200  and members  520  and  540 . The exposed portion may provide a solder pad for connecting a conductor (e.g., an antenna conductor) so that it is electrically coupled to one of sections  120  or  140 . 
     Gap  510  exists between the side walls of sections  110  and  140 . Gap  510  may have a predetermined distance that is maintained between the side walls and brackets  200  during application of the knuckle material. When the material is applied, it can flow in and around brackets  200 , members  520  and  540 , and fill the recesses in which brackets  200  sit. After the material cures, resulting knuckle  144  ( FIG. 5B ) is provided. 
       FIG. 5B  shows a perspective view of knuckle  144  in accordance with an embodiment of the invention. As shown, knuckle  144  physically couples sections  110  and  140  together but ensures they are electrically isolated by the distance of gap  510 . Portions of contact members  520  and  540  are exposed even though knuckle  144  is cured. It is understood that contact members  520  and  540  are optional and are not necessary for each knuckle. For example, knuckle  124  may not encapsulate any contact members. 
       FIG. 6A  shows a perspective view of knuckle  124  of  FIG. 1  in accordance with an embodiment of the invention. Knuckle  124  can encapsulate two brackets (not shown) and mechanically couple sections  130  and  120  together, and ensures they are electrically isolated by gap  710 .  FIGS. 6B and 6C  show a perspective view and a top view, respectively of brackets  200  and  250  mounted to sections  120  and  130 , respectively. Bracket  250  is dimensioned a little smaller than its counterpart bracket  200  and thus may be better suited for being mounted in curved sections, such as section  120 . 
       FIG. 7  shows a cross-sectional view taken along line A-A of  FIG. 6A . The cross-sectional view shows side wall  732  of section  130 , knuckle  124 , and bracket  200 . Also shown is vertical center axis  701  which is aligned with plate member  240 . Horizontal center axis  702  is also shown to bisect plate member  240 . Equal thicknesses of knuckle  124  exist on both sides of center axes  701  and  702 . This ensures knuckle  124  is even distributed about the bracket and provides optimal mechanical coupling strength. 
       FIGS. 8A-C  show various illustrative views of interface  112  in accordance with embodiments of the invention.  FIG. 8A  shows bracket  250  mounted to section  120  and it also shows integrated coupling structure  850 .  FIGS. 8B and 8C  show knuckle  114  interfacing with bracket  250  and coupling structure  850 . 
       FIG. 9  shows a two-shot knuckle according to an embodiment of the invention. As shown, two-shot knuckle  910  mechanically couples together sections  920  and  930 . Sections  920  and  930  can be any suitable conductive section each having a coupling structure (e.g., a bracket welded thereto or an integrally formed structure). For example, sections  920  and  930  can each have a bracket welded thereto. As another example, section  920  can have a bracket welded thereto and section  930  can have an integrally formed structure. In yet another example, both sections  920  and  930  can have integrally formed structures. 
     Two-shot knuckle  910  includes first shot component  912  and second shot component  918 . First shot component  912  physically couples sections  920  and  930  together. That is, first shot  912  provides the mechanical coupling since it encapsulates both coupling structures similar to that as discussed above in connection with  FIGS. 5-8 . In addition, it is constructed from a material that is better suited for coupling sections  920  and  930  than second shot component  918 . For example, first shot material  912  may be constructed from a glass-filled nylon and second shot material may be constructed from an unfilled nylon. Both first and second shots  912  and  918  electrically isolate sections  920  and  930  from each other. 
     Second shot  918  resides in a second shot retaining region  913  and within the gap existing between sections  920  and  930 . Since second shot  918  resides in the gap, it is the part visible to a user when an electronic device using knuckle  910  and sections  920  and  930  is fully assembled. As such, second shot  918  serves as a cosmetic component and can be constructed from a material having any suitable color. For example, second shot  918  can be white, blue, purple, red, green, orange, yellow, or gray. 
       FIG. 10  shows a cross-sectional view of knuckle  910  taken along line A-A of  FIG. 9  in accordance with an embodiment of the invention.  FIG. 10  shows first shot component  912  having second shot retaining regions  913 . Second shot retaining regions  913  can be cavities formed in component  912  during the first shot molding process. These cavities serve as coupling mechanisms that enable second shot component  918  to anchor itself to first shot component  912 . In some embodiments, second shot component  918  may be constructed from a material that is unable to chemically bond to first shot material  912  after it cures. This may be because it is undesirable to remelt any portion of first shot  912  after it has cured. Thus, by leveraging second shot retaining regions  913 , second shot  918  anchors itself to first shot  912  when it cures. 
       FIGS. 11A-B  through  14 A-B show illustrative views of a series of process steps used to manufacture a two-shot knuckle in accordance with an embodiment of the invention. The figures ending with the letter A show a top view and figures ending with the letter B show a cross-sectional view. The two-shot knuckle can be knuckle  910  of  FIG. 9 , though it is understood that any other suitable knuckle can be created. 
       FIGS. 11A-B  show the result after first shot component  1112  has been applied and cured. First shot component  1112  is shown abutting the inside surface of sections  1120  and  1130  as well as protruding through gap  1150 . In addition, first shot component  1112  is shown encapsulating coupling structure  1140  (shown here as a bracket). Also shown as part of first shot component  1112  are second shot retaining regions  1113 . Retaining regions  1113  may be formed by a metal insert, which is held in place during the molding process. After the mold cures, the metal inserts are removed, thereby leaving behind retaining regions  1113 . 
       FIGS. 12A-B  show cosmetic portion  1114  machined out of first shot component  1112 . Formation of cosmetic portion  1114  also cut sections  1120  and  1130  to size so that gap  1160  of a predetermined distance exists therebetween. Gap  1160  may have a predetermined distance that is greater than the distance of gap  1150 .  FIG. 12B  shows that cosmetic portion  1114  cut first shot component  1112  at an angle at its edges.  FIG. 12B  also illustrates how cutting tool  1170  machines away cosmetic portion  1114  by following path  1172 . The angled cut provides a pocket into which material of the second shot component can flow into during molding of the second shot component. 
       FIGS. 13A-B  show how second shot component  1118  anchors itself to first shot component  1112  using second shot retaining regions  1113 .  FIGS. 13A-B  also show second shot component  1118  extending through gap  1160 .  FIGS. 14A-B  show knuckle  1110  after a finishing process has been applied to remove any excess second shot  1118 . 
       FIG. 15  shows an illustrative process for mechanically coupling two conductive sections together with a two-shot knuckle in accordance with an embodiment of the invention. Beginning at step  1510 , a first conductive section having a first coupling structure and a first side wall is provided. At step  1515 , a second conductive section having a second coupling structure and a second side wall is provided. The first and second sections are secured in place so that a first gap exists between the first and second side walls. The first coupling structure can be a bracket or an integrated structure. Likewise, the second coupling structure can be a bracket or an integrated structure. 
     At step  1520 , a first shot component is molded into the first gap, the first shot component interfacing with the first and second coupling structures to physically couple the first and second conductive sections together, and comprising a second shot retaining region. The first shot component can be injection molded, for example. 
     At step  1530 , a cosmetic region is machined out of the first shot component and the first and second conductive sections, the cosmetic region comprising a second gap that exists between the first and second side walls. Then, at step  1540 , a second shot is molded into the cosmetic region. 
     At step  1550 , a cosmetic finishing process is applied to the sections and knuckle. This process can involve trimming away a portion of the knuckle and polishing the sections to meet a desired aesthetic appeal. 
     It should be understood that the processes described above are merely illustrative. Any of the steps may be removed, modified, or combined, and any additional steps may be added or steps may be performed in different orders, without departing from the scope of the invention. 
     The described embodiments of the invention are presented for the purpose of illustration and not of limitation.

Metadata:
Filing Date: 20190909
Publication Date: 20201222
Grant Date: 20201222
Priority Date: 20110831
Inventors: JARVIS, DANIEL WILLIAM
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1698", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/2258", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/026", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1698", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1698", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/0283", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01Q1/521", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0283", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0283", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/2258", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1698", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0283", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/026", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/521", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 47743429