PATENT DOCUMENT

Publication Number: US-8646637-B2
Application Number: US-12775208-A
Country: US
Kind Code: B2

Title: Perforated substrates for forming housings

Abstract:
A housing for an electronic device as well as methods for forming the housing are disclosed. The housing can be formed from a substrate having perforations to assist in adhering components internal to the housing. The substrate is typically a multi-layer substrate having at least two layers. In one embodiment, an inner layer of the multi-layer substrate can be provided with perforations. The perforations can them be used to adhere internal features to the multi-layer substrate. The internal features can be used for attaching parts or components to the multi-layer substrate, thereby securing the parts or components to the multi-layer substrate and thus the housing.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising: a housing comprising a curved interior surface having a plurality of anchor cavities formed therein, each of the anchor cavities having an undercut geometry; and an attachment feature configured to secure an internal component to the curved interior surface using the anchor cavities, the attachment feature comprising: a body comprising: an engagement surface having a curved surface corresponding to the curved interior surface of the housing; and a plurality of anchor portions continuous with the body and protruding from and perpendicular to the engagement surface, each of the plurality of anchor portions having a flared geometry configured to engage with the undercut geometry of each of a corresponding one of the plurality of anchor cavities providing a multi-axis securing force that secures the attachment feature to the curved interior surface of the housing. 
     
     
       2. An electronic device attachment feature as recited in  claim 1 , wherein the body further comprises:
 a fastening surface positioned opposite the engagement surface and configured to receive the internal component, the fastening surface having a shape in accordance with a portion of the internal component such that the internal component is secured to the curved interior surface of the housing, wherein the shape of the fastening surface is different from the shape of the engagement surface. 
 
     
     
       3. An electronic device as recited in  claim 1 , wherein the flared geometry of each of the anchor portions lock each of the anchor portions within corresponding anchor cavities. 
     
     
       4. An electronic device as recited in  claim 1 , wherein attachment feature comprises a hook configured to engage with the internal component. 
     
     
       5. An electronic device as recited in  claim 1 , wherein the plurality of anchor portions do not extend past an exterior surface of the housing. 
     
     
       6. An electronic device housing assembly, comprising:
 a housing arranged to house an internal component within an internal cavity, the housing comprising:
 a curved interior surface comprising a plurality of perforations formed therein, each of the plurality of perforations having an undercut geometry; and 
 
 an attachment feature configured to secure the internal component to the curved interior surface of the housing, the attachment feature comprising a body portion, the body portion comprising:
 an engagement surface having a shape corresponding to the curved interior surface of the housing, and 
 a plurality of embedded members continuous with the body portion and extending away from and perpendicular to the engagement surface, each of the plurality of embedded members having a flared geometry configured to engage with the undercut geometry of each of a corresponding one of the plurality of perforations providing a multi-axis locking force configured to secure the attachment feature to the curved interior surface of the housing. 
 
 
     
     
       7. A housing assembly as recited in  claim 6 , wherein the body portion further comprises:
 a fastening surface positioned opposite the engagement surface and configured to receive the internal component, the fastening surface having a shape in accordance with a portion of the internal component, wherein the shape of the fastening surface is different from the shape of the engagement surface. 
 
     
     
       8. A housing assembly as recited in  claim 6 , wherein the attachment feature comprises a hook configured to engage with the internal component. 
     
     
       9. A housing assembly as recited in  claim 6 , wherein the plurality of embedded members are contained within and do not extend past an exterior surface of the housing. 
     
     
       10. A housing assembly for an electronic device, housing assembly comprising: a housing arranged to house an internal component within an internal cavity and having a curved portion, the curved portion comprising: a first layer having a curved inner surface corresponding to an inner surface of the housing, a second layer coupled with the first layer, and a plurality of perforations provided through the first layer and that do not extend within the second layer, each of the plurality of perforations having an undercut geometry; and an attachment feature configured to receive the internal component, the attachment feature comprising: a body comprising: an engagement surface having a shape corresponding to the curved inner surface of the housing; and a plurality of embedded portions contiguous with the body and extending away from and perpendicular to the engagement surface, each of the plurality of embedded portions having a flared geometry configured to engage with the undercut geometry of each of a corresponding one of the plurality of perforations providing a multi-axes securing force configured to secure the attachment feature to the curved inner surface of the housing. 
     
     
       11. A housing assembly as recited in  claim 10 , wherein the attachment features secures the internal component to the inner layer. 
     
     
       12. A housing assembly as recited in  claim 10 , wherein the plurality of perforations are within the curved portion of the housing. 
     
     
       13. A housing assembly as recited in  claim 10 , wherein the perforations each have a cross-sectional width of 1-5 mm. 
     
     
       14. A housing assembly as recited in  claim 10 , wherein the attachment feature comprises a hook configured to engage with the internal component. 
     
     
       15. A housing assembly as recited in  claim 10 , wherein sidewalls of each of the embedded portions are defined by the first layer and a bottom portion of each of the embedded portions is defined by the second layer. 
     
     
       16. A housing assembly as recited in  claim 10 , further comprising:
 a fastening surface positioned opposite the engagement surface and configured to receive the internal component, the fastening surface having a shape in accordance with a portion of the internal component, wherein the shape of the fastening surface is different from the shape of the engagement surface. 
 
     
     
       17. A housing assembly as recited in  claim 10 , wherein the second layer has an outer surface corresponding to an outer surface of the housing.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 61/046,260, filed Apr. 18, 2008, entitled “Perforated Substrates for Forming Housings”, which is herein incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to forming housing for electronic devices. 
     2. Description of the Related Art 
     The manufacture of devices that include metal parts often includes the formation of features, e.g., complex mechanical structures, on surfaces of the metal parts. In order to ensure the structural integrity of such features, the features are often affixed to the surfaces of the metal parts using an adhesive material. By way of example, an internal feature has been obtained and glued in an appropriate location on a surface of a metal parts or housings. 
     Alternatively, internal features have been welded to the surface of metal parts or housings. Utilizing a welding process to attach internal features to metal parts is limiting in terms of the number and the complexity of the internal features that is possible using a welding technique. Furthermore, the cosmetic quality of a metal part may be degraded as a result of a welding process. For instance, the heat associated with a welding process may alter the shape and/or the color of a metal part. 
     Internal features may also be formed using an injection molding process. When a manufacturing process includes an injection molding process, a through-hole may be formed in a metal part or housing, and a plastic or a resin may be injected through the through-hole. The plastic or resin may form a feature on one side of the metal part, e.g., a metal sheet, while additional plastic or resin may form an undercut on the other side of the metal sheet. The undercut, in cooperation with the plastic or resin that hardens in the through-hole, may effectively serve to anchor or otherwise hold the feature in place. Often, the side of a metal sheet on which an undercut is located may be arranged to be exposed. That is, the side of a metal sheet on which an undercut is located may be an external surface of an apparatus or device. As such, the presence of an undercut on the side of the metal sheet may be aesthetically undesirable, e.g., when the metal sheet is arranged to serve a cosmetic purpose. 
     SUMMARY OF THE INVENTION 
     The invention pertains to a housing for an electronic device as well as methods for forming the housing. The housing can be formed from a substrate (material) having perforations to assist in adhering components internal to the housing. The substrate is typically a multi-layer substrate having at least two layers. In one embodiment, an inner layer of the multi-layer substrate can be provided with perforations. The perforations can them be used to adhere internal features (e.g., internal structures or attachment structures) to the multi-layer substrate. The internal features can be used for attaching parts or components to the multi-layer substrate, thereby securing (e.g., anchoring) the parts or components to the multi-layer substrate and thus the housing. 
     The invention may be implemented in numerous ways, including, but not limited to, as a method, system, device, or apparatus. Example embodiments of the present invention are discussed below. 
     As a method for forming an enclosure for a consumer electronic product, one embodiment can, for example, include at least the acts of: obtaining an inner layer and an outer layer; imposing a plurality of perforations to the inner layer; combining the perforated inner layer with the outer layer to form a multi-layer substrate; forming the enclosure for the consumer electronic product from the multi-layer substrate; and molding internal features onto the perforated inner layer of the enclosure. 
     As an assembly, one embodiment of the invention can, for example, include at least: a multi-layer substrate having at least a first layer and a second layer; a plurality of perforations provided in the first layer; and at least one structural feature adhered to the first layer at least in part by one or more of the perforations. 
     As a portable electronic device, one embodiment of the invention can, for example, include at least an electronic component, and a housing arranged to house the electronic component. The housing can include at least a multi-layer substrate having at least a first layer and a second layer, a plurality of perforations provided in the first layer, and at least one internal feature adhered to the first layer at least in part by one or more of the perforations. 
     As a housing for a portable electronic device, one embodiment of the invention can, for example include at least: a multi-layer substrate having at least a first layer and a second layer; a plurality of perforations provided in the first layer; and at least one internal feature formed on or attached to the first layer at least in part by one or more of the perforations. 
     Various aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, in which: 
         FIG. 1A  is a cross-sectional side-view diagrammatic representation of a housing structure according to one embodiment of the invention. 
         FIG. 1B  is a cross-sectional side-view diagrammatic representation of a housing structure according to another embodiment of the invention. 
         FIG. 1C  is a cross-sectional side-view diagrammatic representation of a housing structure according to another embodiment of the invention. 
         FIG. 1D  is a cross-sectional side-view diagrammatic representation of a housing structure according to another embodiment of the invention. 
         FIG. 1E  is a cross-sectional side-view diagrammatic representation of a housing structure according to another embodiment of the invention. 
         FIG. 1F  is a cross-sectional side-view diagrammatic representation of a housing structure according to another embodiment of the invention. 
         FIG. 1G  is a cross-sectional side-view diagrammatic representation of a housing structure according to another embodiment of the invention. 
         FIGS. 2A-2D  are partial top views of multi-layer substrates according to one embodiment of the invention. 
         FIG. 3  is a flow diagram of an enclosure manufacturing process according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Exemplary embodiments of the present invention are discussed below with reference to the various figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes, as the invention extends beyond these embodiments. 
     The invention pertains to a housing for an electronic device as well as methods for forming the housing. The housing can be formed from a substrate (material) having perforations to assist in adhering components internal to the housing. The substrate is typically a multi-layer substrate having at least two layers. In one embodiment, an inner layer of the multi-layer substrate can be provided with perforations. The perforations can them be used to adhere internal features (e.g., internal structures or attachment structures) to the multi-layer substrate. The internal features can be used for attaching parts or components to the multi-layer substrate, thereby securing (e.g., anchoring) the parts or components to the multi-layer substrate and thus the housing. 
     In one embodiment, internal features can be adhered to an exposed surface of a multi-layer substrate. One or more internal features may be formed or attached to the multi-layer substrate. Examples of internal features include, but are not limited to:, structural members, frames, screw bosses, bridges, snaps, flexures, flanges, shelves, tapers, cavities, and/or pockets. 
     In one embodiment, a multi-layer substrate having at least one metal layer may be a portion or a component of a housing of an electronic device. A multi-layer substrate that is a portion of a housing of an electronic device may be a bezel section, a front section, and/or a back section of the housing. 
     In one embodiment, the housing being formed from multi-layer substrates can be a metal part, housing, or sheet having multiple layers, where at least one of the layers is metal. The metal part, housing, or sheet may serve a structural and/or a cosmetic purpose. That is, an enclosure, housing, or sheet having multiple layers may have a purely structural purpose, a purely aesthetic purpose, or both a structural purpose and an aesthetic purpose. For ease of discussion, a metal part, housing or sheet will generally be described as a housing, although it should be appreciated that a metal element may be substantially any suitable metal component associated with a device or an apparatus, such as a housing, a sheet, or an insert. 
     The invention can be utilized in a variety of different devices (e.g., electronic devices) including, but not limited to including, portable and highly compact electronic devices (i.e., portable electronic devices) with limited dimensions and space. In one embodiment, a device may be a laptop computer, a tablet computer, a media player, a mobile phone (e.g., cellular phone), a personal digital assistant (PDA), substantially any handheld electronic device, a computer mouse, a keyboard, a remote control, substantially any computer accessory, and/or substantially any computer peripheral. Typically, the electronic devices include at least one electrical component inside its housing. The electrical component can, for example, be an integrated circuit or circuit board. Examples of integrated circuits include memory, processor (microprocessor or controller), ASIC, and various others. 
       FIG. 1A  is a cross-sectional side-view diagrammatic representation of a housing structure  100  according to one embodiment of the invention. The housing structure  100  includes a multi-layer substrate  102 . The multi-layer substrate  102  can, for example, represent a material that is suitable for use as an enclosure (e.g., housing) for an electronic device, such as a consumer electronic device. 
     The multi-layer substrate  102  has an outer layer  104  and an inner layer  106 . The outer layer  104  can serve as the outer surface of the enclosure and can be referred to as a cosmetic layer (or cosmetic surface). The inner layer  106  is normally not visible once the enclosure (e.g., housing) for the electronic device is fabricated or assembled. 
     The inner layer  106  of the multi-layer substrate  100  also includes first perforations  108  and second perforations  110 . The first perforations  108  and the second perforations  110  can be staggered. Hence, as illustrated in  FIG. 1A , the first perforations  108  are exposed in the cross-sectional view, while the second perforations  110  are hidden (i.e., broken lines). As shown in  FIG. 1A , the first perforations  108  and the second perforations  110  can extend completely through the inner layer  106 . However, in other embodiments, the first perforations  108  and the second perforations  110  need not extend completely through the inner layer  106 . 
     In one embodiment, the outer layer  104  and the inner layer  106  are separate metal layers that are pressed (e.g., clad) together to form the multi-layer substrate  102 . In an alternative embodiment, the outer layer  104  and the inner layer  106  can be laminated together, such as in a multi-layer sheet. In still another embodiment, the outer layer  104  can be adhered to the inner layer  106  using a bonding action or an adhesive. 
     The outer layer  104  and the inner layer  106  of the multi-layer substrate  102  can be formed from the same or different materials. In one embodiment, the outer layer  104  and the inner layer  106  are both the same metal, such as stainless steel, cooper, or aluminum. In another embodiment, the outer layer  104  and the inner layer  106  can utilize different metals. For example, with regard to  FIG. 1A , the outer layer  104  can be stainless steel, and the inner layer  106  can be aluminum. Since different metals can be used, the properties or characteristics of the different layers  104  and  106  having different metals can be advantageously utilized to form housings. For example, the outer layer  104  can be stainless steel, and the inner layer  106  can be aluminum. In addition, one or both of the outer layer  104  and the inner layer  106  can be a non-metal material. However, the non-metal materials need to withstand the subsequent processing of the multi-layer substrate to form the enclosure. Since different metals or other materials can be used, the properties or characteristics of the different layers  104  and  106  can be advantageously utilized to form housings. 
       FIG. 1B  is a cross-sectional side-view diagrammatic representation of a housing structure  120  according to one embodiment of the invention. The housing structure  120  is similar to the housing structure  100  illustrated in  FIG. 1A  with the addition of internal features  122  attached to the multi-layer substrate  102 . The internal features  122  can be adhered to the multi-layer substrate  102  through use of one or more embedded members  124 . As illustrated in the cross-sectional side view shown in  FIG. 1B , one or more of the embedded members  124  can be provided in one or more of the first perforations  108  and used to adhere the corresponding internal feature  122  to the multi-layer substrate  102  of the housing structure  120 . In one implementation, the internal features  122  are formed on the inner layer  106  of the multi-layer substrate  102  and held securely to the inner layer  106  by the embedded member  124  provided within the corresponding one or more of the first perforations  108 . In other words, the embedded member  124  provided within the corresponding one or more of the first perforations  108  serves to mechanically retrain the internal feature  122  to the multi-layer substrate, and thus the housing structure  120 . In one implementation, one or more of the internal features  122  as well as the corresponding one or more embedded members  124  can be concurrently formed by molding process. As a particular example, for a given internal feature  122 , the internal feature  122  and the corresponding one or more embedded members  124  can be injection molded such that the internal feature  122  and the corresponding one or more embedded members  124  can be integrally formed. Accordingly, the internal features  122  can be secured to the multi-layer substrate  102  by one or more corresponding embedded members  124  that are provided within one or more of the perforations  108 ,  110 . In one embodiment, the internal features  122  and the embedded members  124  are plastic or resin features that can be molded (e.g., insert-molded, injection-molded) onto the inner layer  106 . 
     The internal features  122  can be utilized as binding features or attachment features to assist in the assembly of a housing that utilizes one or more other parts that are to be attached or bounded to the housing structure  120 . As illustrated in  FIG. 1B , the internal features  122  can be geometrically complex internal features that are suitable for operation as binding features or attachment features. 
       FIG. 1C  is a cross-sectional side-view diagrammatic representation of a housing structure  130  according to one embodiment of the invention. The housing structure  130  is similar to the housing structure  120  illustrated in  FIG. 1B  with the addition of an additional piece  132  bound to the multi-layer substrate  102 . The additional piece  132  is adhered to the multi-layer substrate  102  through use of the internal features  122 . The additional piece  132  can be a structural component or an electronic component. The additional piece  132  can be attached to, or effectively molded around, the internal features  122 . If the additional piece  132  a structural component that is molded, the additional piece  132  can, for example, be formed by injection molding. The additional piece  132  may, in one embodiment, be arranged to include complex mechanical features (not shown) which can be complementary to the features  122 . Although  FIG. 1C  illustrates the additional piece  132  being bound to the multi-layer substrate  102 , it should be understood that, in general, one or more internal features can be bound to the multi-layer substrate  102  using one or more internal features  122 . 
       FIG. 1D  is a cross-sectional side-view diagrammatic representation of a housing structure  140  according to one embodiment of the invention. The housing structure  140  is similar to the housing structure  100  illustrated in  FIG. 1A . The multi-layer substrate  102  has the outer layer  104  and the inner layer  106 . The inner layer  106  of the multi-layer substrate  102  also includes first perforations  108 ′ and second perforations  110 ′ that are angled (e.g., tapered or trapezoidal) in shape. For example, the shape of the perforations  108 ′ and  110 ′ have an undercut profile as illustrated in  FIG. 1D . Advantageously, the angled perforations can provide greater holding capability as compared to perforations that are straight (or not angled). The first perforations  108 ′ and the second perforations  110 ′ can also be staggered. As shown in  FIG. 1D , the first perforations  108 ′ and the second perforations  110 ′ can extend completely through the inner layer  106 . However, in other embodiments, the first perforations  108 ′ and the second perforations  110 ′ need not extend completely through the inner layer  106 . 
       FIG. 1E  is a cross-sectional side-view diagrammatic representation of a housing structure  160  according to one embodiment of the invention. The housing structure  160  is similar to the housing structure  140  illustrated in  FIG. 1D  with the addition of internal features  162  attached to the multi-layer substrate  102 . The internal features  162  can be adhered to the multi-layer substrate  102  through use of one or more embedded members  164 . As illustrated in the cross-sectional side view shown in  FIG. 1E , one or more of the embedded members  164  can be provided in one or more of the first perforations  108 ′ and used to adhere the corresponding internal feature  162  to the multi-layer substrate  102  of the housing structure  160 . In one implementation, the internal features  162  are formed on the inner layer  106  of the multi-layer substrate  102  and held securely to the inner layer  106  by embedded member  164  provided within the corresponding one or more of the first perforations  108 . For example, the internal features  162  as well as the corresponding one or more embedded members  164  can be formed by molding process. As a particular example, for a given internal feature  162 , the internal feature  162  and the corresponding one or more embedded members  164  can be injection molded such that the internal feature  162  and the corresponding one or more embedded members  164  can be integrally formed. Accordingly, the internal features  162  can be secured to the multi-layer substrate  102  by one or more corresponding embedded members  164  that extend into one or more of the perforations  108 ′,  110 ′. 
       FIG. 1F  is a cross-sectional side-view diagrammatic representation of a housing structure  180  according to one embodiment of the invention. The housing structure  180  is similar to the housing structure  160  illustrated in  FIG. 1E  with the addition of one or more additional internal features  182  attached to the multi-layer substrate  102 . Like the internal features  162 , the one or more additional internal features  182  can be adhered to the multi-layer substrate  102  through use of one or more embedded members  184 . As illustrated in the cross-sectional side view shown in  FIG. 1F , one or more of the embedded members  184  can be provided in one or more of the first perforations  108 ′ and used to adhere the corresponding internal feature  182  to the multi-layer substrate  102  of the housing structure  160 . The various internal features  162 ,  182  being utilized can have different geometries. For example, the internal features  162  have one geometry, while the internal feature has another different geometry. 
       FIG. 1G  is a cross-sectional side-view diagrammatic representation of a housing structure  190  according to one embodiment of the invention. The housing structure  190  is similar to the housing structure  140  illustrated in  FIG. 1D  although at least an illustrated portion of the multi-layer substrate  102 ′ of the housing structure  190  is curved. The outer layer  104 ′ and the inner layer  106 ′ are also curved. The inner layer  106 ′ also includes the perforations  108 ′. The housing structure  190  illustrated in  FIG. 1G  also has an internal feature  192  adhered to the multi-layer substrate  102 ′ through use of one or more embedded members  194 . 
       FIGS. 2A-2D  are partial top views of multi-layer substrates according to one embodiment of the invention. The partial top views illustrated in  FIGS. 2A-2D  illustrate inner-layers of the multi-layer substrates having a plurality of perforations. The perforations in the different multi-layer substrates have different arrangements or shapes. The multi-layer substrates illustrated in  FIGS. 2A-2D  are, for example, suitable for use as the multi-layer substrate  102  in  FIGS. 1A-1F . 
       FIG. 2A  is a partial top view of a multi-layer substrate  200  according to one embodiment of the invention. The multi-layer substrate  200  has a plurality of circular perforations  202 . In this embodiment, the circular perforations  202  are arranged in a uniform pattern of offset rows. Further, in this embodiment, the circular perforations  202  are uniformly provided across an inner-layer of the multi-layer substrate  200 . 
       FIG. 2B  is a partial top view of a multi-layer substrate  220  according to another embodiment of the invention. The multi-layer substrate  220  has a plurality of circular perforations  222  arranged in a pattern. For example, the circular perforations  222  can be provided on the inner-layer around the outer peripheral portion of the multi-layer substrate  220 . The pattern of these circular perforations  222  provided on the multi-layer substrate  220  is in a box configuration. It should be noted, however, that the pattern of the circular perforations  222  can take any of a wide variety of patterns. 
       FIG. 2C  is a partial top view of a multi-layer substrate  240  according to another embodiment of the invention. The multi-layer substrate  240  has a plurality of circular perforations  242  provided at a first region  246  of the inner-layer of the multi-layer substrate, and a plurality of circular perforations  244  provided at a second region  248  of the inner-layer of the multi-layer substrate. For example, as illustrated in  FIG. 2C , the set of perforations  242  can be provided at the first region  246  to facilitate attachment of one and more internal features to that location of the multi-layer substrate  240 . Similarly, the set of perforations  244  can be provided at the second region  248  to facilitate attachment of one or more other internal features to that location of the multi-layer substrate  240 . 
       FIG. 2D  is a partial top view of a multi-layer substrate  260  according to still another embodiment of the invention. The multi-layer substrate  260  has a plurality of perforations  262 . The perforations  262  illustrated in  FIG. 2D  are plus-shaped. Hence, the shape of the perforations can, in general, vary with implementation. For example, the perforations can not only be circular or plus-shaped but also square, oval, trapezoidal, triangular, star-shaped and many more. The geometric complexity of the shapes can range from relatively simple (e.g., circular, oval, square) to relatively complex (e.g., plus-shaped, star-shaped). Moreover, although all the perforations  262  illustrated in  FIG. 2D  are plus-shaped, the perforations on the multi-layer sheet need not be all the same shape but can be a mixture of different shapes. 
       FIG. 3  is a flow diagram of an enclosure manufacturing process according to one embodiment of the invention. In the enclosure manufacturing process  300  operates to produce a multi-layer substrate that can be utilized as an enclosure for a consumer electronic device. The multi-layer substrate can, for example, represent the multi-layer structure  102 ,  102 ′ of any of the housing structures  100 ,  120 ,  130 ,  140 ,  160 ,  180  and  190  illustrated in  FIGS. 1A-1G . 
     The enclosure manufacturing process  300  can initially obtain  302  an inner layer and an outer layer for the enclosure to be manufactured. Next, perforations can be imposed  304  to the inner-layer. The perforations are, in one embodiment, small holes that extend through the inner layer. The diameter of the holes can, in one implementation, be approximately 1-5 mm in diameter. In another implementation, the diameter of the holes can be approximately 2-3 mm in diameter. As noted above, the geometric shape of the perforations can vary (e.g., circular, oval, star-shaped, plus shaped, etc.). In one embodiment, the perforations can be imposed  304 , i.e., formed, by passing the inner layer through a rolling press. In another embodiment, the perforations can be imposed  304  by chemically removing portions of the inner layer to yield the perforations. For example, chemical removal of portions can be performed by a chemical etch process. In still another embodiment, the perforations can be imposed  304 , i.e., formed, by being laser-etched. Alternatively, in another embodiment, the inner layer can be obtained such that the perforations are already formed therein. 
     The perforated inner-layer can then be combined  306  with the outer layer to form a multi-layer substrate. The inner layer and the outer layer can be pressed (e.g., clad) together, laminated together, or adhered together. Thereafter, using the multi-layer substrate, an enclosure for a consumer electronic device can be formed  308  from the multi-layer substrate. In one implementation, the enclosure can be formed  308  through a mechanical process, such as stamping, punching, pressing and the like. 
     Once the enclosure for the consumer electronic device has been formed  308 , one or more internal features can be molded  310  onto the perforated inner-layer of the enclosure. Advantageously, these one or more internal features can be molded to the inner-layer with a single molding tool. In other words, multiple internal features can be formed by a single molding tool all without having to remove the enclosure to form the different internal features. These one more internal features can be formed singly or concurrently by use of the single molding tool. The internal features formed within housing structures are utilized to bind the other components to the housing structure, and thus the consumer electronic device. For example, the internal features can serve to mechanically constrain internal parts to the enclosure. The other components and/or internal parts can be structural components or electronic components. Following the molding  310  of the one or more internal features to the enclosure, the enclosure manufacturing process  310  can end. 
     Additional information on housings having multiple layers can be found in: (i) U.S. patent application Ser. No. 11/964,652, filed on Dec. 26, 2007, entitled “Methods and Systems for Forming a Dual Layer Housing”, which is incorporated herein by reference for all purposes; (ii) U.S. Provisional Patent Application No. 60/949,780, filed on Jul. 13, 2007, entitled “Dual Layer Housing”, which is incorporated herein by reference for all purposes; and (iii) U.S. Provisional Patent Application No. 61/023,375, filed on Jan. 24, 2008, entitled “Method and Systems for Forming Housings from Multi-layer Materials”, which is incorporated herein by reference for all purposes. 
     The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Metadata:
Filing Date: 20080527
Publication Date: 20140211
Grant Date: 20140211
Priority Date: 20080418
Inventors: WEBER DOUGLAS
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C45/14344", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23P19/04", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C2045/14327", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B37/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C45/14344", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2038/047", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/1671", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3481", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/4998", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24289", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14311", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/1671", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14811", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2038/047", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2553/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B38/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0217", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14811", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2705/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14311", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4998", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24008", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B37/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B38/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2705/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/1657", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/1657", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2553/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/14327", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3481", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24008", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/24289", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 40942522