PATENT DOCUMENT

Publication Number: US-9451065-B2
Application Number: US-201414244297-A
Country: US
Kind Code: B2

Title: Adaptive plug for edge protection

Abstract:
Housings for electronic devices including adaptive plugs, and the use of adaptive plugs in methods of manufacturing housings. The housing may include an opening, and an adaptive plug releasably positioned within the opening. A method of forming a housing may include forming an opening within the housing, disposing a curable material within the opening of the housing, and curing the material to form an adaptive plug. The adaptive plug may be positioned within the opening of the housing. The method may also include performing at least one surface treatment on the housing. A method of protecting an edge of an opening in a housing may include providing the housing including the opening, forming an adaptive plug within the opening of the housing, and forming a barrier on the edge of the opening using the adaptive plug.

Claims:
We claim: 
     
       1. A method of forming a housing, comprising:
 forming an opening within the housing and causing a bur to be formed on an outer surface of the housing; 
 disposing a curable material within a portion of the opening of the housing and forming a bead portion of the curable material on the outer surface of the housing, wherein the bead portion is coupled to the bur; 
 curing the material to form an adaptive plug, wherein the adaptive plug is positioned within the opening of the housing; 
 performing at least one surface treatment on the housing, the at least one surface treatment comprising one or more of polishing the outer surface of the housing; buffing the outer surface of the housing; and sand blasting the outer surface of the housing; and 
 removing the bead portion of the adaptive plug, the bead portion positioned on the outer surface of the housing. 
 
     
     
       2. The method of  claim 1 , wherein the forming of the opening within the housing further comprises:
 machining the opening through the housing from an inner surface of the housing to the outer surface of the housing 
 such that the bur is in alignment with the opening. 
 
     
     
       3. The method of  claim 2 , wherein the disposing of the curable material within the portion of the opening of the housing further comprises dispensing the curable material within the opening from the inner surface of the housing to the outer surface of the housing. 
     
     
       4. The method of  claim 1 , further comprising removing the adaptive plug formed within the opening of the housing. 
     
     
       5. The method of  claim 4 , wherein the removing of the adaptive plug formed within the opening of the housing further comprises removing the plug from the opening of the housing through the inner surface of the housing. 
     
     
       6. The method of  claim 4 , wherein the removing of the adaptive plug formed within the opening of the housing further comprises:
 exposing the housing and the adaptive plug to a liquid; 
 applying a force to the adaptive plug positioned within the opening of the housing; and 
 peeling the adaptive plug from the opening of the housing. 
 
     
     
       7. The method of  claim 4 , wherein the removing of the adaptive plug formed within the opening of the housing further comprises burning the adaptive plug from the opening of the housing. 
     
     
       8. The method of  claim 4 , further comprising:
 in response to removing the adaptive plug formed within the opening of the housing, performing a fine buffing process on the housing including the opening. 
 
     
     
       9. The method of  claim 1 , wherein the disposing of the curable material within the opening of the housing further comprises one of:
 spraying the curable material within the opening of the housing; 
 dunking the housing including the opening within a supply of the curable material; or 
 locally applying the curable material within the opening of the housing. 
 
     
     
       10. A method of forming a housing, comprising:
 removing a portion of the housing to define an aperture within the housing, wherein the removing creates a bur on a top surface of the housing; 
 disposing a curable material within a portion of the aperture and forming a bead portion of the curable material on the to surface of the housing, thereby coupling the bead portion of the curable material to the bur; 
 curing the curable material to form an adaptive plug disposed within the aperture; 
 mechanically treating the top surface of the housing by performing at least one of:
 polishing the top surface of the housing; 
 buffing the top surface of the housing; and 
 sand blasting the top surface of the housing; and 
 
 separating the bead portion of the adaptive plug from the top surface of the housing. 
 
     
     
       11. The method of  claim 10 , wherein the curable material is substantially malleable. 
     
     
       12. The method of  claim 10 , wherein the curing comprises curing the curable material using ultraviolet light. 
     
     
       13. The method of  claim 10 , wherein the curing comprises curing the curable material by increasing a temperature of the curable material. 
     
     
       14. The method of  claim 10 , wherein the removing of the portion of the housing further comprises:
 machining the aperture through the housing from an inner surface of the housing to the top surface of the housing such that the bur is aligned with the aperture. 
 
     
     
       15. The method of  claim 14 , wherein the disposing of the curable material within the portion of the aperture further comprises dispensing the curable material within the aperture from the inner surface of the housing to the top surface of the housing. 
     
     
       16. A method of forming a housing, comprising:
 generating a hole within the housing such that a bur is formed on an exterior surface of the housing; 
 depositing a curable material along a contour of the hole and forming a bead portion of the curable material on the exterior surface of the housing, wherein the bead portion of the curable material is affixed to the bur; 
 hardening the material to define an adaptive plug positioned within the hole; 
 modifying a surface texture of the housing by at least one of:
 polishing the exterior surface of the housing; 
 buffing the exterior surface of the housing; and 
 sand blasting the exterior surface of the housing; and 
 
 detaching the bead portion of the adaptive plug from the exterior surface of the housing. 
 
     
     
       17. The method of  claim 16 , wherein the hole comprises one of:
 a through hole; 
 a blindhole; or 
 a counter bore. 
 
     
     
       18. The method of  claim 16 , wherein the depositing of the curable material further comprises three-dimensionally (3D) printing the adaptive plug with the hole. 
     
     
       19. The method of  claim 16 , further comprising removing the adaptive plug formed within the hole. 
     
     
       20. The method of  claim 19 , wherein the removing of the adaptive plug formed within the hole further comprises removing the plug from the hole of the housing through the inner surface of the housing. 
     
     
       21. The method of  claim 16 , wherein the depositing of the curable material within the hole of the housing further comprises one of:
 spraying the curable material within the hole of the housing; 
 submerging the hole within a supply of the curable material; or 
 locally applying the curable material within the hole of the housing.

Description:
TECHNICAL FIELD 
     The disclosure relates generally to housings for electronic devices, and more particularly, to housings for electronic devices including adaptive plugs, and the use of adaptive plugs in methods of manufacturing housings for electronic devices. 
     BACKGROUND 
     When manufacturing component housings, the tolerance and/or dimensions of the various parts of the housing are very important. For example, when manufacturing a housing for an electronic device, the various apertures of the housing may require very specific and detailed tolerances and/or dimensions. These specific tolerances and/or dimensions may be dependent on the functionality and/or the aesthetic appeal of the apertures. The apertures for the housing of the electronic device may require an edge that is substantially smooth (e.g., rounded) or substantially sharp (e.g., abrupt transition between surfaces). When it is desired that the edge of the apertures in the housing be smooth or rounded, the apertures and/or the edge may not require additional care or protection when processing the housing. That is, the edge of the apertures may be substantially exposed to surface treatment processes (e.g., grinding, polishing, buffing) performed on the housing and the surface including the apertures. As a result, in addition to performing surface treatment processes on the cosmetic surface of the housing and/or removing burs formed during the formation process of the apertures within the housing, the surface treatments processes performed on the housing may also smooth-out or round the edge of the apertures by removing a portion of the material forming the housing. 
     However, when it is desired that the edge of the apertures in the housing be substantially sharp, the apertures and/or the edge of the apertures may need to be protected when performing surface treatment processes on the housing. Conventional processes for protecting the edge of the apertures include utilizing a mechanical fitting to be positioned within the apertures. More specifically, after the aperture is formed within the housing and the burs formed on the surface around the aperture are removed from the housing, a mechanical fitting is inserted within the aperture to protect the edge of the aperture during subsequent processing of the housing. 
     Ideally, the fitting may prevent subsequent surface treatment processes (e.g., grinding, polishing, buffing) from removing material of the housing on the edge of the aperture. However, like the apertures of the housing, each mechanical fitting includes a specific tolerance. Where the dimensions for the aperture of the housing and/or the mechanical fitting are not within the desired tolerance, the mechanical fitting may not sufficiently protect the edge of the aperture. For example, where the length or diameter of the mechanical fitting is below the desired tolerance and/or the corresponding feature of the aperture of the housing is above the desired tolerance, the edge of the aperture may not be completely protected by the fitting. As a result, the subsequent surface treatments processes performed on the housing may undesirable remove material from the aperture&#39;s edge, which is not completely protected by the mechanical fitting. Conversely, where the mechanical fitting is above the desired tolerance and/or the aperture of the housing is below the desired tolerance, the mechanical fitting may create a shadow defect on the housing during subsequent processing or, may not fit in the aperture at all. A mechanical fitting may be custom made to ensure proper fit and/or edge protection for each housing utilizing a fitting. However, this process may be very time consuming and very expensive, especially when it is desired to produce high volumes of the housing including the aperture. 
     SUMMARY 
     Generally, embodiments discussed herein are related to housings for electronic devices including adaptive plugs, methods for forming housings for electronic devices using adaptive plugs, and methods for protecting openings in housings for electronic devices using adaptive plugs. The adaptive plug utilized within the housings may include a curable material that may be disposed within an opening of the housing and subsequently cured within the opening and/or on a portion of the housing. By including a material that may be cured within the opening, the adaptive plug may be custom fit to any opening of the housing. That is, because of the process and/or material used to form the adaptive plug, the adaptive plug may completely protect the opening and/or the opening&#39;s edge of the housing, no matter the dimensions and/or tolerance of the opening in the housing. This may substantially ensure that the opening and/or the opening&#39;s edge is protected when performing subsequent surface treatment processes on the housing. Additionally, the adaptive plug may be utilized in automated processes for forming the housing including the opening. As such, the adaptive plug may provide a desired protection when processing the housing, while performing processes for producing high volumes of housings. 
     One embodiment may include a housing. The housing may include an opening formed within the housing, and an adaptive plug releasably positioned within the opening. 
     Another embodiment may include a method of forming a housing. The method may include forming an opening within the housing, disposing a curable material within the opening of the housing, and curing the material to form an adaptive plug. The adaptive plug may be positioned within the opening of the housing. The method may also include performing at least one surface treatment on the housing. 
     A further embodiment may include a method of protecting an edge of an opening in a housing. The method may include providing the housing including the opening, and forming an adaptive plug within the opening of the housing. The adaptive plug may include a curable material. The method may also include forming a barrier on the edge of the opening using the adaptive plug. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1A  shows an illustrative front view of an electronic device according to embodiments. 
         FIG. 1B  shows an illustrative perspective view of the electronic device of  FIG. 1A , according to embodiments. 
         FIG. 2  is a flow chart illustrating a method of forming a housing for an electronic device using an adaptive plug. 
         FIG. 3  is a flow chart illustrating a method of protecting an edge of an opening of an electronic device housing using an adaptive plug. 
         FIGS. 4A-4J  show illustrative cross-section views of a housing for an electronic device, undergoing processes of forming as depicted in  FIGS. 2 and 3 , according to embodiments. The cross-section views of the housing for the electronic device are taken along line  4 A- 4 J in  FIG. 1B . 
         FIG. 5A  shows an illustrative front view of an electronic device according to additional embodiments. 
         FIG. 5B  shows an illustrative perspective view of the electronic device of  FIG. 5A , according to additional embodiments. 
         FIGS. 6A-6G  show illustrative cross-section views of a housing for an electronic device, undergoing processes of forming as depicted in  FIGS. 2 and 3 , according to additional embodiments. The cross-section views of the housing for the electronic device are taken along line  6 A- 6 G in  FIG. 5B . 
     
    
    
     It is noted that the drawings of the invention are not necessarily to scale. The drawings are intended to depict only typical aspects of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims 
     The following disclosure relates generally to housings for electronic devices, and more particularly, to housings for electronic devices including adaptive plugs, and the use of adaptive plugs in methods of manufacturing housings for electronic devices. 
     The adaptive plug utilized within the housings may include a curable material that may be disposed within an opening of the housing and subsequently cured within the opening and/or on a portion of the housing. By including a material that may be cured within the opening, the adaptive plug may be custom fit to any opening of the housing. That is, because of the process and/or material used to form the adaptive plug, the adaptive plug may completely protect the opening and/or the opening&#39;s edge of the housing, independent of the dimensions and/or tolerance of the opening in the housing. This may substantially ensure that the opening and/or the opening&#39;s edge is protected when performing subsequent surface treatment processes on the housing. Additionally, the adaptive plug may be utilized in automated processes for forming the housing including the opening. As such, the adaptive plug may provide a desired protection when processing the housing, while performing processes for producing high volumes of housings. 
     These and other embodiments are discussed below with reference to  FIGS. 1A-6G . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1A  shows an illustrative front view of one example of an electronic device  100 , according to embodiments. In the illustrated embodiment, electronic device  100  is implemented as a smart telephone. Other embodiments can implement electronic device  100  differently, such as, for example, as a laptop or desktop computer, a tablet computing device, a gaming device, a display, a digital music player, a wearable computing device or display, a health monitoring device, and so on. 
     Electronic device  100  includes a housing  102  at least partially surrounding a display  104  and one or more buttons  106  or input devices. More specifically, as shown in  FIG. 1A , electronic device  100  may include display  104  and button  106  formed on a front or outer surface  108  of housing  102 . Housing  102  can form outer surface  108  or partial outer surface  108  and protective case for the internal components of the electronic device  100 , and may at least partially surround display  104 . Housing  102  can be formed of one or more components operably connected together, such as a front piece and a back piece. Alternatively, housing  102  can be formed of a single piece operably connected to display  104 . Additionally, housing  102  may be formed from a variety of material including, but not limited to: aluminum, stainless steel, ceramic zirconia, and precious metals, including gold, silver, and platinum. 
     Display  104  can be implemented with any suitable technology, including, but not limited to, a multi-touch sensing touchscreen that uses liquid crystal display (LCD) technology, light emitting diode (LED) technology, organic light-emitting display (OLED) technology, organic electroluminescence (OEL) technology, or another type of display technology. Button  106  can take the form of a home button, which may be a mechanical button, a soft button (e.g., a button that does not physically move but still accepts inputs), an icon or image on a display, and so on. Further, in some embodiments, button  106  can be integrated as part of a cover glass of electronic device  100 . 
     Turning to  FIG. 1B , an illustrative perspective view of a portion of electronic device  100  is shown according to embodiments. Electronic device  100  may also include a plurality of openings  110  formed through housing  102 . Openings  110  in housing  102  of electronic device  100  may provide access from external components of electronic device  100  to internal components. As discussed herein, openings  110  formed in housing  102  may be formed directly through outer surface  108  of housing  102  using conventional material removal processes including, but not limited to: drilling, milling, cutting, and grinding. Additionally, as discussed herein, openings  110  formed in housing  102  may be configured in a variety of conventional shapes (e.g., circle, oval, polygon, etc.), as well as custom shapes or designs (e.g., crescent, star, cross, etc.). 
     In a non-limiting example, as shown in  FIG. 1B , electronic device  100  may include a battery charging port  112  included in housing  102 . More specifically, battery charging port  112  may include opening  110  formed through a bottom portion  118  of housing  102 . As shown in  FIG. 1B , bottom portion  118  may include a substantially flat portion of outer surface  108  of housing  102 . That is, bottom portion  118  may be substantially flat and may be included in outer surface  108  of housing  102 . Battery charging port  112  may be configured to receive a portion of a charging device (not shown) for charging the battery (not shown) of electronic device  100 . That is, battery charging port  112  positioned on bottom  118  of housing  102  may be in electronic communication with a battery (not shown) of electronic device  100  included within an internal cavity (see,  FIGS. 4A-4J ) of housing  102 , and may be coupled to a charging device. The charging device may provide an electric current to electronic device  100  to substantially charge the battery positioned within housing  102  of electronic device  100 . 
     Additional openings  110  formed in housing  102  of electronic device  100  may include additional components of electronic device  100 . That is, as shown in  FIG. 1B , bottom  118  of housing  102  may include a speaker  120  and a microphone  122  of electronic device  100  formed from openings  110 . More specifically, two distinct openings  110  may be formed in bottom  118  on opposite sides of battery charging port  112 , and may include speaker  120  and microphone  122  for electronic device  100 , respectively. Speaker  120  may include any conventional speaker assembly utilized by electronic device  100  for projecting sound to a user of electronic device  100 . Additionally, microphone  122  may include any conventional microphone system that may be utilized by electronic device  100  to receive audio input from a user of electronic device  100 . 
     Openings  110  formed through housing  102  for the various components (e.g., battery charging port  112 , speaker  120 , microphone  122 ) of electronic device  100  may be formed with specific design features. More specifically, each opening  110  formed through outer surface  108  of housing  102  may be created to include specific dimensions, shapes, curvatures and/or tolerances. These specific design features may be dependent, at least in part, on the function and/or the aesthetics of the electronic device  100  and/or the component of the electronic device  100  that utilized the specific opening  110 . 
     In a non-limiting example, as shown in  FIG. 1B , opening  110  which forms speaker  120  of electronic device may include a substantially oval shape. Additionally, speaker edge  124  of opening  110  of speaker  120  may be substantially curved or rounded. That is, when forming housing  102  to include opening  110  for speaker  120 , the speaker edge  124  of opening  110  may undergo surface treatments to substantially curve or round-out speaker edge  124  prior to speaker  120  being installed in electronic device  100  and/or electronic device  100  is made available to a user. As discussed herein, the surface treatments performed on housing  102  may include, but are not limited to: polishing, buffing, sand blasting, grinding, planing, and milling. 
     In the non-limiting example, opening  110  for speaker  120  of electronic device  100  may include a substantially curved or rounded speaker edge  124  as a result of speaker  120  being configured to provide an output signal (e.g., sound). That is, no external component may interact or contact speaker  120  formed in opening  110 . As such, and for ease of manufacturing, opening  110  of speaker  120  may include a substantially curved or rounded speaker edge  124 . It is understood, however, that curved edges for openings  110  formed in electronic device  100  may not be limited to openings  110  that may not interact and/or connect with external components of electronic device  100 . That is, functionality may not be the only characteristic which determines the design features and specifics of openings  110  formed in electronic device  100 . In an additional non-limiting embodiment, speaker edge  124  of opening  110  may include a sharp edge (e.g., abrupt transition between sidewall and outer surface  108 ) for speaker  120  of electronic device  100 . 
     In another non-limiting example, opening  110  forming battery charging port  112  may include a port edge  126  that may be substantially sharp. As discussed herein, the term “substantially sharp” or “sharp edge” may be used interchangeably and may be understood as an edge that includes a substantially perpendicular or 90° transition between outer surface  108  of bottom portion  118  and sidewalls  128  (see,  FIGS. 4B and 4C ) of opening  110  forming battery charging port  112 . In the non-limiting example, opening  110  forming battery charging port  112  may include substantially sharp port edge  126  as a result of functional design features and/or aesthetic design features. With respect to functional design features, opening  110  forming battery charging port  112  may include substantially sharp port edge  126  to aid in the coupling or mating of the charging device (not shown) to battery charging port  112 . That is, by including a substantially sharp port edge  126  for battery charging port  112 , the charging device may not easily become disconnected or be misaligned when being coupled to the electronic device  100 . With respect to the aesthetic design feature, it may be desired to form substantially sharp port edge  126  for battery charging port  112  to continue the aesthetic design of “hard” or sharp edges for the entire electronic device  100 . 
     Substantially sharp edges (e.g., port edge  126 ) for openings  110  of electronic device  100  may be formed using an adaptive plug (see,  FIGS. 4E-4I ) during the manufacturing of housing  102  of electronic device  100 . Turning to  FIG. 2 , a process of forming housing  102  (see,  FIG. 1B ) using an adaptive plug, may now be discussed. Specifically,  FIG. 2  is a flowchart for depicting a sample method  200  for form forming housing  102  using an adaptive plug. 
     In operation  202 , an opening may be formed in a housing. More specifically, an opening may be formed completely through the body of the housing for an electronic device. The forming of the opening may include machining (e.g., drilling, cutting, milling) the opening through the housing from an inner surface of the housing to an outer surface of the housing. Additionally, by machining the opening through the housing, a bur may be formed on the outer surface of the housing, in alignment with the opening. That is, when opening is completely formed through outer surface of the housing via the machining process, a bur or undesirable, excess of material may be formed on the outer surface of the housing aligned with and/or adjacent to the opening. 
     Although the opening is discussed herein as being formed completely through the body of the housing for an electronic device, it is understood that the opening may not be formed completely though the housing. That is, in non-limiting examples, the opening my include a blindhole, a counter bore, or a recess formed or machined into the housing for the electronic device. 
     In operation  204 , a curable material may be disposed within the opening formed within the housing. The curable material may be disposed within the opening formed with the housing by dispensing the curable material from the inner surface of the housing up to the outer surface of the housing. The curable material disposed within the opening formed within the housing may be substantially malleable or in liquid form. Thus, the curable material may take the shape and/or completely fill up the opening during the disposing process in operation  204 . The disposing of the curable material within the opening of the housing in operation  204  may be accomplished using a variety of distinct processes. In non-limiting examples, the curable material may be sprayed within the opening of the housing, or the curable material may be locally applied within the opening of the housing. In an additional, non-limiting example, the curable material may be injection molded into the opening of the housing. In a further, non-limiting example, the housing, include the opening, may be immersed in a volume of the curable material, such that the curable material is positioned within and/or substantially fills the opening formed within the housing. 
     As discussed herein, the disposing of the curable material in operation  204  may also include forming a bead portion of the curable material disposed on an outer surface of the housing. The bead portion of the curable material may be coupled to the bur formed on the outer surface of the housing during operation  202 . Additionally as discussed herein, bead portion may be formed on an inner surface of the housing as well. Bead portion may be formed on the inner surface dependent on a variety of factors including, but not limited to: to size or dimension of the opening, the shape of the opening, the material composition of the curing material (discussed herein), and the material composition of the housing. As discussed herein, the bead portion of the curable material may be formed by disposing an excess amount of the curable material within the opening, and allowing the excess curable material to flow out of the opening. Additionally as discussed herein, the bead portion formed from the excess portion of the curable material may be held on the surface of the housing by the surface tension of the opening and the surface and/or the viscosity properties of the curable material. 
     In operation  206 , the curable material positioned within the opening of the housing may be cured to form an adaptive plug. The adaptive plug formed from the cured material may be positioned within the opening of the housing. The curing of the curable material may include curing the curable material positioned within the opening of the housing, as well as, curing the bead portion of the curable material formed on the outer surface of the housing, and where applicable, curing the bead portion of the curable material formed on the inner surface of the housing. As discussed herein, by curing the curable material positioned within the opening, the adaptive plug formed from the curable material may take the exact shape of the opening formed within the housing, and the bead portion of the curable material/adaptive plug may substantially surround the burs formed on the outer surface of the housing in operation  202 . 
     As discussed herein, the curing of the curable material in operation  206  may be dependent on the material composition of the curable material. In a non-limiting example where curable material includes an ultraviolet (UV) curable material, the curing of the curable material in operation  206  may include exposing the UV curable material to a UV light. In an additional non-limiting example where curable material includes an thermo-curable material, the curing of the curable material in operation  206  may include increasing the temperature of the thermo-curable material. 
     As discussed in detail herein with respect to  FIG. 3 , the curing, forming and/or positioning of the adaptive plug within the opening of the housing may aid in protecting and/or forming the sharp edge of the opening when forming the housing of the electronic device. That is, and as discussed herein, the adaptive plug formed in operation  206  may be substantially hard, and may be utilized in protecting and/or forming a sharp edge for the opening of the housing including the adaptive plug. 
     In operation  208 , at least one surface treatment process may be performed on the housing. More specifically, at least one surface treatment process may be performed on the outer surface of the housing including the opening and the adaptive plug. The surface treatment(s) performed on the housing may include, but is not limited to, at least one of: polishing the outer surface of the housing, buffing the outer surface of the housing, and sand blasting the outer surface of the housing. The surface treatment(s) performed on the housing may also include removing the bur formed on the outer surface of the housing in operation  202 , and removing the bead portion of the adaptive plug coupled to the bur, formed in operation  204 . As discussed in detail with respect to  FIG. 3 , the adaptive plug positioned within the opening of the housing may substantially protect the edge of the opening formed on the outer surface of the housing by preventing the surface treatments performed in operation  208  from being performed on the edge itself. That is, the adaptive plug may protect the edge from the surface treatment(s) performed in operation  208 , and may substantially maintain a sharp edge for the opening formed within the housing. 
     In optional operation  210 , the adaptive plug formed or positioned within the opening of the housing may be removed. More specifically, the adaptive plug positioned within the opening of the housing may be removed through the inner surface of the housing. As discussed herein, the process of removing the adaptive plug from the opening of the housing may be dependent, at least in part, on the material composition of the curable material used to form the adaptive plug (e.g., operations  204 ,  206 ) and/or the material composition of the housing including the opening. In a non-limiting example, removing the adaptive plug formed within the opening of the housing may include burning the adaptive plug from the opening of the housing from the inner surface of the housing. In an additional non-limiting example, removing the adaptive plug formed within the opening of the housing may include: exposing the housing including the adaptive plug to a liquid to soften the adaptive plug; applying a force to the adaptive plug; and peeling the adaptive plug from the opening of the housing. In this non-limiting example, and as discussed herein, the force may be applied to the adaptive plug adjacent the outer surface of the housing by inserting a fastener or pin within the opening, to remove the adaptive plug through the inner surface of the housing. 
     In optional operation  212  (shown in phantom), a fine buffering process may be performed on the housing including the opening. More specifically, once the adaptive plug is removed from the opening of the housing, a fine or final buffering process may be performed on the outer surface of the housing. The fine buffering process may include a minimal or negligible amount of material removal from the outer surface of the housing, such that the sharp edge formed and/or protected by the adaptive plug may remain substantially sharp. 
     Turning to  FIG. 3 , a process of protecting an edge (e.g., port edge  126 ) of opening  110  in housing  102  (see,  FIG. 1B ) using an adaptive plug, may now be discussed. Specifically, and with continued reference to  FIG. 2 ,  FIG. 3  is a flowchart for depicting a sample method  300  for form and/or maintaining a substantially sharp edge for opening  110  of housing  102  using an adaptive plug. 
     In operation  302 , a housing including an opening may be provided. More specifically, a housing including at least one opening may be provided, where the housing may be utilized by an electronic device. The opening included in the housing may be formed in a similar fashion as previously discussed herein with respect to operation  202  in  FIG. 2 . Additionally, the opening of the provided housing may include burs formed on an outer surface of the housing as a result of a process of forming the opening within the housing, as discussed above within respect to operation  202  in  FIG. 2 . 
     In operation  304 , an adaptive plug may be formed within the opening of the housing. More specifically, the forming of the adaptive plug within the opening of the housing may include forming an opening portion of the adaptive plug within the opening and forming a bead portion of the adaptive plug on the outer surface of the housing, where the bead portion is coupled to the burs formed on the outer surface of the housing. The adaptive plug may include and/or be made from a curable material that may be disposed within the opening of the housing, and subsequently cured to form the adaptive plug, as similarly discussed herein within with respect to operations  204  and  206  in  FIG. 2 . In a non-limiting example where the adaptive plug includes a curable material, the forming of the adaptive plug within the opening of the housing may include disposing an arcrylated urethane within the opening of the housing. The disposed arcrylated urethane may be subsequently cured or hardened to form and/or position the adaptive plug within the opening of the housing. 
     In an additional non-limiting example, the positioning of the adaptive plug within the opening of the housing may include three-dimensionally (3D) printing the adaptive plug within the opening of the housing. Specifically, the provided housing including the opening may be positioned within a 3D printer system, and the 3D printer system may subsequently scan and provide, print or dispose a 3D printing material (e.g., thermoplastic, photopolymer) within the opening of the housing to form the adaptive plug. The 3D printer system may print or dispose the adaptive plug within the opening of the housing bases on the exact and/or specific dimensions of the opening, as determined when scanning the housing including the opening. 
     In operation  306 , a barrier on the edge of the opening within the housing may be formed using the adaptive plug. More specifically, the forming of the barrier on the edge of the opening using the adaptive plug may include positioning the adaptive plug adjacent to, or substantially over the edge of the opening, and preventing the edge of the opening from being exposed to subsequent processing of the housing. That is, the adaptive plug may be positioned within the opening of the housing to substantially prevent the edge of the opening from being exposed to additional surface treatment processes that may remove material from the opening and/or the edge of the opening. As discussed herein, the removal of material from the edge of the opening may be unwanted where the edge of the opening formed through the housing may be designed and/or desired to be substantially sharp. The surface treatment processes for which the adaptive plug protects and/or forms the barrier for the edge of the opening within the housing may be substantially similar to those processes discussed in operation  208  of  FIG. 2 . 
     Turning to  FIGS. 4A-4J , with continued reference to  FIGS. 1A and 1B , a housing  102  undergoing various operations of method  200  of  FIG. 2 , and method  300  of  FIG. 3  may be depicted. That is,  FIGS. 4A-4J  may depict the formation of battery charging port  112  in housing  102  for electronic device  100  (see,  FIGS. 1A and 1B ) using an adaptive plug (see,  FIG. 4C ), according to the method  200  of  FIG. 2  and the method  300  of  FIG. 3 .  FIGS. 4A-4J  show an illustrative cross-section view of housing  102  of electronic device  100  taken along line  4 A- 4 J in  FIG. 1B . It is understood that similarly numbered components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
       FIG. 4A  shows a cross-sectional view of a portion of a material forming housing  102  of electronic device (see,  FIG. 1A ) prior to any processing. The portion of the material forming housing  102 , as shown in  FIG. 4A  may form bottom portion  118  of housing  102 . As discussed herein, bottom portion  118  may include outer surface  108  of housing  102 . Additionally, as shown in  FIG. 4A , housing  102  may include an inner surface  130  positioned opposite outer surface  108 . Inner surface  130  of housing  102  may be positioned adjacent and/or substantially surround an internal cavity  132  for electronic device  100 . As discussed herein, internal cavity  132  may contain all of the internal components of electronic device  100 . In a non-limiting example, internal cavity  132  may include the battery (not shown) for electronic device  100  which may be configured to be electrically connected to a charging device (not shown) via battery charging port  112  (see,  FIG. 4J ) formed in housing  102 . As discussed herein, the material used to form housing  102  for electronic device  100  may include aluminum, stainless steel, ceramic zirconia and precious metals, including gold, silver and platinum. In a non-limiting example, the material forming housing  102 , as shown in  FIGS. 4A-4J  may be aluminum. 
       FIG. 4B  shows housing  102  including opening  110 . Opening  110  may be formed completely though housing  102 . More specifically, opening  110  may be formed by any conventional material removal process discussed herein, where opening  110  is formed from inner surface  130  of housing  102  to outer surface  108  of housing  102 . Opening  110  may ultimately form battery charging port (see, item  112  of  FIG. 4J ). Opening  110  formed through housing  102 , as shown in  FIG. 4B , may correspond to operation  202  of  FIG. 2 . Additionally, housing  102  including opening  110 , as shown in  FIG. 4B  may correspond to operation  302  of  FIG. 3 . 
     As a result of forming opening  110  initially through inner surface  130  to outer surface  108  of housing  102 , a bur  134  may be formed on outer surface  108 . As shown in  FIG. 4B , bur  134  may substantially surround and may be in alignment with opening  110 . In some cases, the burr  134  is located along a portion of the edge of the opening  110 . Bur  134  positioned on outer surface  108  of housing  102 , may be formed from the material forming housing  102  and may be formed as a result of the material removal process for forming opening  110 . That is, bur  134  may be formed from a portion of the material forming housing  102  that may not be completely or cleanly removed when forming opening  110  through housing  102 . The burr  134  may protrude from the outer surface  108 , as shown in  FIG. 4B  and/or may also protrude into the void formed by the opening  110 . 
     As shown in  FIG. 4B , and as discussed herein, opening  110  forming battery charging port  112  (see,  FIG. 4J ) may include port edge  126  formed on housing  102 . More specifically, opening  110  forming battery charging port  112  may include port edge  126  formed on outer surface  108  of housing  102  for electronic device  100 . As discussed herein, it may be desired that port edge  126  be substantially sharp once housing  102  is formed and implemented within electronic device  100 . 
       FIG. 4C  shows the beginning process of disposing a curable material  135  within opening  110  of housing  102 . More specifically, curable material  135  may be disposed within opening  110  from inner surface  130  of housing  102  to outer surface  108  of housing  102 . The beginning process of disposing curable material  135  within opening  110  of housing  102 , as shown in  FIG. 4C , may correspond to operation  204  of  FIG. 2 . As discussed herein, curable material  135  may include a material that may be substantially malleable, and capable of being cured to have desired hardness characteristics. In a non-limiting example, curable material  135  may include a material having a viscosity of approximately 25,000 centipoise (cP) when uncured, and may also have a durometer hardness of approximately 55 D when cured. In the non-limiting example, curable material  135  may include arcrylated urethane. However, it is understood that the viscosity, hardness and/or material composition of curable material  135  may vary and may depend on a variety of factors including, but not limited to: the material composition of housing  102 , the dimension of opening  110 , the process of disposing the curable material  135  within opening  110 , and the process for removing the adaptive plug (see,  FIG. 4E ) formed from curable material  135 . As such, the viscosity, hardness and/or material composition of curable material  135  may be distinct from those characteristics and materials provided above. In additional non-limiting examples, curable material  135  may include one of the following materials: ultraviolet curable resin, thermo-curable resin, injection molded polymer, thermoplastics, photopolymers, and epoxy. 
     Additionally as discussed herein, curable material  135  may be disposed within opening  110  of housing  102  using a variety of processes. In a non-limiting example, curable material  135  may be locally applied within opening  110  of housing  102 . More specifically, a dispensing nozzle (not shown) may be positioned within opening  110 , adjacent inner surface  130 , and may gradually fill opening  110  with curable material  135  from inner surface  130  to outer surface  108  of housing  102  (see,  FIGS. 4C-4E ). By disposing curable material  135  within opening  110  from inner surface  130  to outer surface  108 , the likelihood of air bubbles being formed in curable material  135  may be substantially reduced and/or eliminated. It is understood that air bubbles formed in curable material  135  may structural weaken adaptive plug  136  formed from curable material  135 , and/or may negatively affect adaptive plug&#39;s  136  ability to protect and/or form a barrier around port edge  126  of housing  102 . 
     In additional non-limiting example, and as discussed herein, curable material  135  may be disposed within opening  110  of housing  102  by: spraying curable material  135  within opening  110 , immersing a portion of the housing  102  including opening  110  within a supply of curable material  135  to fill opening  110 , and injection molding curable material  135  within opening  110 . In another non-limiting example, curable material  135  may be three-dimensionally (3D) printed within opening  110  of housing  102 . The process in which curable material  135  is disposed within opening  110  of housing  102  may be dependent on a variety of characteristics including, but not limited to: the material composition of curable material  135 , the material composition of housing  102 , the size of opening  110 , and the process for removing adaptive plug  136  formed from curable material  135 . 
     As shown in  FIG. 4C , a bead portion  138  of curable material  135  may be initially formed on inner surface  130  of housing  102 . Bead portion  138  of curable material  135  may be formed on inner surface  130  of housing  102  by depositing a portion of curable material  135  on inner surface  130  around opening  110 . As a result of curable material&#39;s  135  viscosity, bead portion  138  may be formed as a result of the surface tension between curable material  135 , inner surface  130  and opening  110  formed through housing  102 . As discussed herein, bead portion  138  formed on inner surface  130  of housing  102  may aid in fixing adaptive plug  136  formed from curable material  135  within opening  110  when subsequent surface treatment processes are performed on housing  102 . 
     Bead portion  138  may not always be formed on inner surface  130  of housing  102 . That is, in an additional non-limiting example (see,  FIGS. 6A-6G ), bead portion  138  may not be positioned on inner surface  130  of housing  102 , and a portion of curable material  135  may be formed within opening  110  adjacent inner surface  130 . The forming of bead portion  138  on inner surface  130  of housing  102  may be dependent on a variety of factors including, but not limited to: the material composition of curable material  135 , the material composition of housing  102 , the size of opening  110 , the process for disposing curable material  135  within opening  110 , and the process for removing adaptive plug  136  formed from curable material  135 . As shown in  FIG. 4C , bead portion  138  may be formed on inner surface  130  as a result of the small size of opening  110 . That is, and as discussed herein, because opening  110  of housing  102  is relatively small and includes minimal surface area (e.g., sidewalls  128 ) for contacting/coupling to curable material  135  forming adaptive plug  136 , curable material  135  may be deposited on inner surface  130  to form bead portion  138 . Bead portion  138  formed on inner surface  130  of housing  102  may aid in fixing adaptive plug  136  within opening  110  during subsequent surface treatment processes, as discussed herein. 
       FIG. 4D  shows one example of the completed process of disposing a curable material  135  within opening  110  of housing  102 . More specifically, curable material  135  may be disposed completely within opening  110 , and bead portion  138  may be formed on outer surface  108  of housing  102 . The completed process of disposing curable material  135  within opening  110  of housing  102 , as shown in  FIG. 4D , may correspond to operation  204  of  FIG. 2 . As similarly discussed here within respect to bead portion  138  formed on inner surface  130 , bead portion  138  may be formed on outer surface  108  as a result of the viscosity of curable material  135  and/or the surface tension between curable material  135 , outer surface  108 , and opening  110  formed through housing  102 . As discussed herein, bead portion  138  formed on outer surface  108  of housing  102  may aid in protecting and/or forming a barrier for port edge  126  of opening  110  when subsequent surface treatment processes are performed on housing  102 . 
     Additionally, as shown in  FIG. 4D , bead portion  138  formed on outer surface  108  of housing  102  may substantially surround burs  134  formed on outer surface  108  of housing  102 . As discussed herein, when curable material  135  is cured to form adaptive plug  136 , bead portion  138  formed on outer surface  108 , surrounding burs  134 , may become coupled to burs  134  to aid in fixing adaptive plug  136  within opening  110 . 
       FIG. 4E  shows the formation of adaptive plug  136  subsequent to performing a curing process on curable material (see, item  135  of  FIG. 4D ) positioned within opening  110  (see, item  110  of  FIG. 4C ) of housing  102 . More specifically, adaptive plug  136  may be formed by curing curable material  135 , such that adaptive plug  136  is positioned within opening  110  of housing  102 . Additionally, as shown in  FIG. 4E , adaptive plug  136  may include bead portions  138  formed on inner surface  130  and outer surface  108  of housing  102 . The curing of curable material  135  to form adaptive plug  136  within opening  110  of housing  102 , as shown in  FIG. 4E , may correspond to operation  206  of  FIG. 2 . Additionally, the forming of adaptive plug  136  within opening  110  of housing  102 , as shown in  FIG. 4E , may correspond to operation  304  in  FIG. 3 . 
     As shown in  FIG. 4E , adaptive plug  136  may include bead portions  138  formed on inner surface  130  and outer surface  108  of housing  102 , and an opening portion  140  positioned within opening  110 . As discussed herein, bead portion  138  formed on inner surface  130  may aid in fixing adaptive plug within opening  110 , and bead portion  138  formed on outer surface  108  may aid protecting and/or forming a barrier for edge  126  of opening  110 . Opening portion  140  of adaptive plug  136  may be positioned within opening  110  and may be coupled to or contact sidewalls  128  (see,  FIG. 4C ) of opening  110 . That is, opening portion  140  of adaptive plug  136  may include circumference or area substantially equal to a circumference or area of opening  110  to aid in fixing adaptive plug  136  within opening  110 . Additionally, opening portion  140  coupled to or contacting sidewalls  128  of opening  110  may substantially protect sidewalls  128  from being exposed to subsequent surface treatment processes performed on housing  102 , as discussed herein. 
     As shown in enlarged insert portion of  FIG. 4E , adaptive plug  136  may encapsulate the burr and form a substantial seal and/or form a barrier around the portions of housing  102  which adaptive plug  136  contacts. That is, as shown in enlarged insert portion of  FIG. 4E , adaptive plug  136  may be positioned within opening  110  such that opening portion  140  completely contacts (e.g., no gaps or spaces) sidewalls  128  of opening  110 . Additionally, bead portion  138  of adaptive plug  136  position on outer surface  108  may completely contact burs  134  and may be positioned adjacent to and substantially over edge  126  of opening  110 . By positioning adaptive plug  136  substantially over edge  126  of opening  110 , edge  126  may not be exposed and/or adaptive plug  136  may form a barrier on edge  126  to protect edge  126  during subsequent surface treatment processes, as discussed herein. The positioning and/or forming of the barrier on edge  126  by adaptive plug  136  positioned within opening  110 , as shown in  FIG. 4E , may correspond to operation  306  in  FIG. 3 . 
       FIGS. 4F and 4G  show surface treatments being performed on housing  102 . More specifically,  FIG. 4F  shows the process of removing bur  134  formed on outer surface  108  of housing  102  and  FIG. 4G  shows the process of polishing outer surface  108  of housing  102 . The surface treatments performed on outer surface  108  of housing  102 , as shown in  FIGS. 4F and 4G , may correspond to operation  208  of  FIG. 2 . 
     As shown in  FIG. 4F , bur  134  of housing  102  may be removed from the housing  102  and bead portion  138  of adaptive plug  136  formed on outer surface  108  may be removed from housing  102 . Bur  134  formed around opening  110  and bead portion  138  of adaptive plug  136  may be removed from outer surface  108  of housing  102  using any conventional material removal technique(s). In an non-limiting example, a milling process may be performed on outer surface  108  of housing  102  to remove bur  134  formed around opening  110  and bead portion  138  of adaptive plug  136 . A portion of the outer surface  108  of the housing  102  may also be removed by this operation. 
     As a result of removing bur  134  and bead portion  138  formed on housing  102 , outer surface  108  of housing  102  and opening portion  140  of adaptive plug  136  may be in planar alignment. Additionally, as shown in  FIG. 4F , port edge  126  of opening  110  forming battery charging port  112  (see,  FIG. 4J ) may be substantially formed. That is, port edge  126  of opening  110  may no longer be obstructed by bur  134  formed on outer surface  108  of housing  102 . As shown in enlarged insert portion of  FIG. 4F , adaptive plug  136  may continue to provide a barrier and/or may protect port edge  126  of opening  110  during the surface treatment process. That is, as shown in enlarged insert portion of  FIG. 4F , opening portion of adaptive plug  136  may remain in contact with port edge  126  and sidewalls  128  of opening  110  during the performance of the surface treatment process on outer surface  108  of housing  102 . By remaining in contact, and including such a hard material that may not be worn away, adaptive plug  136  positioned within opening  110  may substantially maintain the sharp edge of port edge  126 . More specifically, as a result of positioning adaptive plug  136  in opening  110  while surface treatment processes are performed on outer surface  108  of housing  102 , port edge  126  of opening  110  may not be exposed to the surface treatments, and ultimately, no material may be removed from port edge  126  of opening  110  during the surface treatment process. 
     As shown in  FIG. 4G , a polishing process may be performed on housing  102 . Specifically, as shown in  FIG. 4G , a polishing process may be performed on outer surface  108  of housing  102 , such that a polished portion  142  of outer surface  108  may be exposed. As discussed herein, other non-limiting examples of surface treatments that may be performed on outer surface  108  of housing  102  may include buffing outer surface  08  of housing  102  and sand blasting outer surface  108  of housing  102 . As a result of adaptive plug&#39;s  136  hardness, a plurality of surface treatment processes may be performed on outer surface  108 , without negatively affecting adaptive plug  136  and port edge  126  of opening  110 . 
     As shown in  FIGS. 4H and 4I , adaptive plug  136  may be removed from opening  110  of housing  102 . More specifically, in a non-limiting example as shown in  FIGS. 4H and 41 , a force (F) may be applied to adaptive plug  136  adjacent outer surface  108 , in order to remove adaptive plug  136  through inner surface  130 . The removal of adaptive plug  136  from opening  110  of housing  102 , as shown in  FIGS. 4H and 4I , may correspond to operation  210  of  FIG. 2 . As discussed herein, prior to applying the force (F) to remove adaptive plug  136  from opening  110 , housing  102  may be exposed to a liquid to aid in the removal of adaptive plug  136 . The liquid used to aid in the removal may be dependent upon the material used to form adaptive plug  136 . In an non-limiting example where adaptive plug  136  is formed from arcrylated urethane, the liquid may include warm water, which may ultimately soft adaptive plug  136 . Once softened, the force (F) may be applied to adaptive plug  136 , and adaptive plug  136  may ultimately be peeled from opening  110  of housing  102  through inner surface  130 . More specifically, the bond or coupling between sidewalls  128  of opening  110  and opening portion  140  of adaptive plug  136  may become weakened when housing  102  including adaptive plug is exposed to the liquid. As such, adaptive plug  136  may be peeled or pulled through opening  110  at inner surface  130  of housing  102 . 
       FIG. 4J  shows housing  102  including battery charging port  112 . More specifically,  FIG. 4J  shows housing  102  including battery charging port  112  having a substantially sharp port edge  126  formed on outer surface  108  of housing  102 . As discussed herein, substantially sharp port edge  126  may be formed as a result of including adaptive plug  136  (see,  FIGS. 4E-4I ) in the formation of housing  102 . 
       FIG. 4J  also shows housing  102  subsequent to a fine buffing process being performed on outer surface  108 . More specifically, a fine buffing process may be performed on outer surface  108  of housing  102  just prior to housing  102  being utilized within electronic device  100  (see,  FIG. 1B ). The fine buffing process may remove debris and/or minimal material from housing  102 , and may provide outer surface  108  of housing within a buffed portion  144  over the polished portion  142 . As a result of the minimal material removal accomplished by the fine buffing process, port edge  126  of opening  110  forming battery charging portion  112  may remain substantially sharp without the need for adaptive plug  136  to be positioned within opening  110 . The fine buffing process of outer surface  108  of housing  102 , as shown in  FIG. 4J , may correspond to optional operation  212  in  FIG. 2 . 
       FIGS. 5A and 5B  show a distinct electronic device  500 , according to additional embodiments. Electronic device  500 , as shown in  FIGS. 5A and 5B , may be distinct from electronic device  100  shown in  FIGS. 1A and 1B , and may configured as a media player. Although distinct from electronic device  100 , electronic device  500  of  FIGS. 5A and 5B  may include substantially similar components as electronic device  100 . More specifically, electronic device  500  may include a housing  502 , a display  504 , at least one button  506 , openings  510  formed through bottom portion  518 , battery charging port  512 , speaker  520 , and other features. It is understood that similarly named components or similarly numbered components may function in a substantially similar fashion, may include similar materials and/or may include similar interactions with other components. Redundant explanation of these components has been omitted for clarity. 
     Electronic device  500  may include distinct features and/or components as electronic device  100  (see,  FIG. 1B ). As shown in  FIG. 5B , and with comparison to  FIG. 1B , electronic device  500  may include substantially curved portions of housing  502 . More specifically, as shown in  FIG. 5B , bottom portion  518  of housing  502  may be substantially curved. That is, outer surface  508  of bottom portion  518  of housing  502  may be substantially curved on electronic device  500 . Bottom portion  518  may be substantially curved by design for aesthetic purposes. 
     Additionally as shown in  FIG. 5B , and with comparison to  FIG. 1B , electronic device  500  may include headphone port  546 . More specifically, an opening  510  may be formed through curved, bottom portion  518  of housing  502  in order to form headphone port  546  within electronic device  500 . Headphone port  546  may be in coupled to an headphone system (not shown) positioned within housing  502 , and may be configured receive a headphone jack (not shown) for allowing a user to listen to electronic device  500  audio via personal headphone. The headphone system coupled to headphone port  546  may include any conventional electronic audio system typically used within electronic devices. 
     Headphone port  546  may include headphone port edge  548  positioned on outer surface  508  of curved bottom portion  518 . Similar to port edge  126  of battery charging port  112  in  FIG. 1B , headphone port edge  548  of headphone port  546  may be designed to include a substantially sharp edge. However, distinct from port edge  126  (see,  FIG. 1B ), headphone port edge  548  may be formed on a curved surface (e.g., curved bottom portion  518 ) of housing  502  for electronic device  500 . As discussed herein, headphone port edge  548  may include a substantially sharp edge for function and/or aesthetic purposes. 
     Turning to  FIGS. 6A-6G , with continued reference to  FIGS. 5A and 5B , a housing  502  undergoing various operations of method  200  of  FIG. 2 , and method  300  of  FIG. 3  may be depicted. That is,  FIGS. 6A-6G  may depict the formation of headphone port  546  in housing  502  for electronic device  500  (see,  FIGS. 5A and 5B ) using adaptive plug  136  (see,  FIG. 6C ), according to the method  200  of  FIG. 2  and the method  300  of  FIG. 3 .  FIGS. 6A-6G  show an illustrative cross-section view of housing  502  of electronic device  500  taken along line  6 A- 6 G in  FIG. 5B . It is understood that similarly numbered components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. Additionally, it is understood that housing  502  may undergo substantially similar processes as housing  102 , as discussed herein with respect to  FIGS. 4A-4J . As such, redundant explanation of these processes has been omitted for clarity. 
       FIG. 6A  shows a portion of a material forming housing  502  of electronic device  500  prior to any processing. As shown in  FIG. 6A , as discussed herein, bottom portion  518  of housing  502  may be substantially curved. In a non-limiting example, the material shown in  FIG. 6A  for forming housing  502  for electronic device  500  may be ceramic zirconia. 
       FIG. 6B  shows housing  502  including opening  510 . Opening  510  may be formed completely through housing  502  using any conventional material removal process. As discussed herein, opening  510  may be formed from inner surface  530  to outer surface  508  of curved, bottom portion  518  of housing  502 . As a result, bur  534  may be formed on outer surface  508  of curved, bottom portion  518  and may substantially surround and/or be aligned with opening  510 . Opening  510  formed through housing  502 , as shown in  FIG. 6B , may correspond to operation  202  of  FIG. 2 . Additionally, housing  502  including opening  510 , as shown in  FIG. 6B , may correspond to operation  302  of  FIG. 3 . 
       FIG. 6C  shows the process of disposing curable material  535  within opening  510  of housing  502 . Curable material  535  may be disposed within opening  510  in similar processes as discussed herein with respect to  FIG. 4C . Additionally, the process of disposing curable material  535  within opening  510 , as shown in  FIG. 6C , may correspond to operation  204  of  FIG. 2 . 
     With comparison to  FIG. 4C , and as discussed herein, curable material  535  may be disposed within opening  510  without the formation of bead portion  538  (see,  FIG. 6D ) on inner surface  530  of housing  502 . That is, as shown in  FIG. 6C , curable material  535  may be deposited adjacent to, but not directly on inner surface  530  of housing  502 , and as such, may not form bead portion  538  on inner surface  530  of housing  502 . With comparison to battery charging port  112  of  FIG. 4C , opening  510  used to form headphone port  546  may be substantially large, and may include a larger surface area (e.g., sidewalls  528 ) for contacting and/or being coupled to adaptive plug  536  formed from curable material  535 . As a result of the increased surface area to contact adaptive plug  536  within opening  510 , adaptive plug  536  formed from curable material  535  may be fixed within opening  510  without the need for bead portion  538  on inner surface  530 . As such, curable material  535  may not be disposed onto inner surface  530  of housing  502 . 
       FIG. 6D  shows the formation of adaptive plug  536  subsequent to performing a curing process of curable material  535  (see,  FIG. 6C ) positioned within opening  510  of housing  502 . More specifically, adaptive plug  536  may be formed by curing curable material  535 , such that adaptive plug  536  is positioned within opening  510  of housing  502 . Additionally, as shown in  FIG. 6D , adaptive plug  536  may include bead portions  538  formed on outer surface  508  of curved bottom portion  518  of housing  502 . The curing of curable material  535  to form adaptive plug  536  within opening  510  of housing  502 , as shown in  FIG. 6D , may correspond to operation  206  of  FIG. 2 . Additionally, the forming of adaptive plug  536  within opening  510  of housing  502 , as shown in  FIG. 6D , may correspond to operation  304  in  FIG. 3 . 
     As similarly discussed herein with respect to  FIG. 4E , adaptive plug  536  may include bead portion  538  formed on outer surface  508 , that may be coupled to bur  534 . Additionally, as discussed herein, adaptive plug  536  may form a seal and/or form a barrier around the portions of housing  502  which adaptive plug  536  contacts. More specifically, adaptive plug  536  may form a barrier on headphone port edge  548  of opening  510  forming headphone portion  546 , and sidewalls  528  of opening  510 . 
       FIG. 6E  shows a surface treatment being performed on housing  502 . More specifically,  FIG. 6E  shows the process of removing (e.g., milling) bur  134  formed on outer surface  508  of curved, bottom portion  518  of housing  102 , and removing bead portion  538  of adaptive plug  536 . As similarly discussed herein with respect to  FIG. 4F , the surface treatment performed on outer surface of curved, bottom portion  518  of housing  502 , as shown in  FIG. 6E , may correspond to operation  208  of  FIG. 2 . 
       FIG. 6F  shows adaptive plug  536  being removed from opening  510  of housing  502 . More specifically, and distinct from the removal process discussed herein with respect to  FIGS. 4H and 4I , adaptive plug  536  may be removed by burning adaptive plug  526  from opening  510  of housing  502 . In the non-limiting example, housing  502  may be made from ceramic zirconia, which includes a melting temperature significantly higher than the arcrylated urethane used to form adaptive plug  536 . As such, a heat source  550  may utilized to burn adaptive plug  536  from opening  510 . As shown in  FIG. 6F , heat source  550  may include a laser positioned within opening  510 , through inner surface  530 , that may expose adaptive plug  536  to a laser beam that may burn or incinerate the adaptive plug  536 . As a result, the removal process of adaptive plug  536 , as shown in  FIG. 6F , may be accomplished by burning adaptive plug  536  from opening  510  of housing  502 , without negatively effecting housing  502  by exposure to heat source  550  (e.g., laser). The removal of adaptive plug  536  from opening  510  of housing  502 , as shown in  FIG. 6F , may correspond to operation  210  of  FIG. 2 . 
       FIG. 6G  shows housing  502  including headphone port  546 . More specifically, housing  502 , as shown in  FIG. 6G , may include headphone port  546  including a substantially sharp headphone port edge  548  formed on outer surface  508  of curved, bottom portion  518  of housing  502 . Within comparison to  FIG. 4J , housing  502  of  FIG. 6G  may not include a fine buffing portion, as accomplished by performing a fine buffing process, as discussed in optional operation  212  in  FIG. 2 . As such, once adaptive plug  536  is removed from opening  510  forming headphone port  546  in housing  502 , housing  502 , as shown in  FIG. 6G  may be utilized by electronic device  500 . 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20140403
Publication Date: 20160920
Grant Date: 20160920
Priority Date: 20140403
Inventors: VAN ASSELDONK BRANDON J.
ROSENTHAL BRETT A.
HUANG CHIEN-MING
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/0274", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4998", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/4998", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 54211009