PATENT DOCUMENT

Publication Number: US-9871898-B2
Application Number: US-201313890141-A
Country: US
Kind Code: B2

Title: Ceramic cover for electronic device housing

Abstract:
An electronic device having an enclosure formed from at least one ceramic cover and a peripheral structure adjacent the periphery of the ceramic cover is disclosed. The peripheral structure can be secured adjacent to the ceramic cover with an attachment member. The ceramic cover can include a recess to receive the attachment member. The peripheral structure can be molded adjacent the ceramic cover so that a gapless interface can be formed between the peripheral structure and the periphery of the ceramic cover.

Claims:
The invention claimed is: 
     
       1. An electronic device enclosure, comprising:
 a unitary ceramic cover formed from a sapphire material, comprising:
 a top surface; 
 a bottom surface; and 
 a blind recess formed into the bottom surface and extending toward the top surface, the blind recess defined by a recessed surface and interior sidewalls extending from the recessed surface to a bottom surface of the unitary ceramic cover; 
 
 a peripheral structure overmolded over a portion of the unitary ceramic cover and into the blind recess and that defines an attachment member secured within the blind recess along the interior sidewalls and the recessed surface; and 
 an outer housing member coupled with the peripheral structure opposite the unitary ceramic cover, wherein 
 a thickness of the unitary ceramic cover is less than 5 millimeters. 
 
     
     
       2. The electronic device enclosure as recited in  claim 1 , wherein the ceramic cover comprises at least one of sapphire and zirconia. 
     
     
       3. The electronic device enclosure as recited in  claim 1 , wherein the blind recess is a laser ablated recess extending into a peripheral portion of the ceramic cover. 
     
     
       4. The electronic device enclosure as recited in  claim 1 ,
 wherein the attachment member comprises at least one tenon configured to extend into the blind recess of the ceramic cover. 
 
     
     
       5. The electronic device enclosure as recited in  claim 4 , wherein the tenon comprises an angled tenon, and wherein the recess comprises a dovetail recess configured to interlock mechanically with the angled tenon. 
     
     
       6. The electronic device enclosure as recited in  claim 4 , wherein the tenon of the attachment member is integral with a portion of the peripheral structure. 
     
     
       7. The electronic device enclosure as recited in  claim 1 , wherein overmolding of the peripheral structure to the ceramic cover results in a gap-free interface. 
     
     
       8. The electronic device enclosure as recited in  claim 1 , wherein the peripheral structure comprises a polymer. 
     
     
       9. The electronic device enclosure as recited in  claim 1 , wherein the peripheral structure comprises ceramic fibers. 
     
     
       10. The electronic device enclosure as recited in  claim 1 , wherein the peripheral structure and the ceramic cover have substantially similar coefficients of thermal expansion. 
     
     
       11. The electronic device enclosure as recited in  claim 10 , wherein the peripheral structure comprises additives that are configured to modify the coefficient of thermal expansion of the peripheral structure, the additives including particles or fibers made of a ceramic material. 
     
     
       12. The electronic device enclosure as recited in  claim 1 ,
 wherein the outer housing member has at least one securement feature that mechanically interlocks with the peripheral structure, thereby coupling the peripheral structure and the outer housing member. 
 
     
     
       13. The electronic device enclosure as recited in  claim 1 , wherein
 the ceramic cover has a Vickers hardness that is greater than seven hundred. 
 
     
     
       14. The electronic device enclosure as recited in  claim 1 ,
 wherein the blind recess extends into the ceramic cover by at least 0.3 millimeter. 
 
     
     
       15. The electronic device enclosure as recited in  claim 1 , wherein the ceramic cover is substantially transparent. 
     
     
       16. The electronic device enclosure as recited in  claim 1 , wherein the ceramic cover has an at least partly crystalline structure. 
     
     
       17. The electronic device enclosure of  claim 1 , wherein:
 the top surface of the unitary ceramic cover defines at least a portion of a front of the unitary ceramic cover; and 
 the entire front of the unitary ceramic cover is unobstructed by the peripheral structure. 
 
     
     
       18. The electronic device enclosure of  claim 17 , wherein the entire front of the unitary ceramic cover is completely exposed. 
     
     
       19. A consumer electronic device, comprising:
 a monolithic sapphire cover defining outer and inner surfaces of the consumer electronic device and defining an exterior surface of a display, the monolithic sapphire cover having a recessed channel defined by interior sidewalls extending from the inner surface to a recessed surface that is substantially parallel to, and positioned less than 5 millimeters from, the inner surface; 
 a peripheral structure molded over a side surface of the monolithic ceramic cover and along the interior sidewalls and recessed surface of the recessed channel; and 
 an outer housing member having a securement feature that mechanically interlocks with a portion of the peripheral structure. 
 
     
     
       20. The consumer electronic device as recited in  claim 19 , wherein:
 the ceramic cover comprises at least one of sapphire and zirconia: and 
 the consumer electronic device is one of: a media player, a media storage device, a portable digital assistant, a tablet personal computer, a computer, a mobile phone, a smart phone, a global positioning system unit, or a remote control. 
 
     
     
       21. The consumer electronic device as recited in  claim 19 , wherein a portion of the peripheral structure that is molded along the interior sidewalls and recessed surface defines an attachment member that couples the monolithic sapphire cover and the peripheral structure. 
     
     
       22. An electronic device enclosure, comprising:
 a ceramic cover formed from a sapphire material and defining first and second surfaces of the electronic device enclosure, the ceramic cover having a laser-etched blind recess defined by interior sidewalls extending into the second surface by a distance of less than 5 millimeters and toward the first surface; 
 an overmolded peripheral structure, comprising:
 a side portion overmolded over a side surface of the ceramic cover; and 
 a tenon formed into the laser-etched blind recess and abutting the interior sidewalls to mechanically interlock the ceramic cover and the peripheral structure; and 
 
 an outer housing member coupled with the peripheral structure. 
 
     
     
       23. The electronic device enclosure as recited in  claim 22 , wherein:
 the laser-etched blind recess is a first laser-etched blind recess; 
 the tenon is a first tenon; 
 the electronic device enclosure further comprises:
 a second laser-etched blind recess extending inwardly from the side surface of the ceramic cover; 
 a second tenon member coupled to the side portion of the peripheral section. 
 
 
     
     
       24. The electronic device enclosure as recited in  claim 23 , wherein the first and second laser-etched blind recesses are formed using laser ablation. 
     
     
       25. The electronic device enclosure as recited in  claim 23 , wherein the second tenon is formed into the second laser-etched blind recess of the ceramic cover. 
     
     
       26. The electronic device enclosure as recited in  claim 22 , wherein the laser-etched blind recess is positioned at a peripheral portion of the ceramic cover. 
     
     
       27. The electronic device enclosure as recited in  claim 26 , wherein the tenon in the recess provides a substantially gap-free interface between the peripheral structure and the ceramic cover. 
     
     
       28. The electronic device enclosure as recited in  claim 22 :
 wherein the outer housing member has at least one securement feature that engages the peripheral structure.

Description:
BACKGROUND 
     Portable electronic devices, particularly those that provide wireless data connectivity, are finding increasing popularity. Because of the usefulness of such devices to inform and entertain, their owners may desire to take them wherever they go. While small size may be desired for portability, ruggedness may also be desired along with small size. 
     The foregoing may present design challenges. Smaller and smaller devices made of conventional materials and assembled using conventional techniques may become more fragile. On the other hand, devices built to maximize ruggedness may be too bulky and unattractive to consumers. 
     Unfortunately, however, as portable electronic device continue to be made smaller, thinner and/or more powerful, there remains a continuing need to provide improved structures for portable electronic device housings. 
     SUMMARY 
     The invention pertains to an electronic device having an enclosure formed from at least one ceramic cover and a peripheral structure. The peripheral structure can be provided adjacent the periphery of the ceramic cover. The peripheral structure can be secured adjacent to the ceramic cover with an attachment member. The ceramic cover can include a recess to receive the attachment member. The peripheral structure can be molded adjacent the ceramic cover so that a gapless interface can be formed between the peripheral structure and the periphery of the ceramic cover. The enclosure for the electronic device can be thin yet be sufficiently strong to be suitable for use in electronic devices, such as portable electronic devices. 
     The invention can be implemented in numerous ways, including as a method, system, device, or apparatus. Several embodiments of the invention are discussed below. 
     As an electronic device enclosure, one embodiment can, for example, include at least a ceramic cover for an exposed outer surface for the electronic device enclosure, the ceramic cover having a peripheral portion; an attachment member coupled with the peripheral portion of the ceramic cover; and a peripheral structure configured to provide a support surface for the ceramic cover and to provide side protective surfaces for the ceramic cover. The peripheral structure can be at least partially secured to the ceramic cover by the attachment member. 
     As a consumer electronic device, one embodiment can, for example, include at least a ceramic cover for an exposed outer surface for the consumer electronic device; a peripheral structure configured to provide a support surface for the ceramic cover and to provide side protective surfaces for the ceramic cover, the peripheral structure being at least partially secured to the ceramic cover by a mechanical interlock; and electrical components including at least a controller, a memory, and a display, the display being provided at or adjacent the ceramic cover. 
     As a method for assembling an electronic device, one embodiment of the method can, for example, include at least: obtaining a ceramic member having a top surface and a bottom surface, the top surface providing an outer surface at least a portion of the electronic device; aligning the ceramic member relative to a support structure for the electronic device; and molding a peripheral protective side portion for the electronic device, the peripheral protective side portion being molded adjacent the periphery of the ceramic member and adjacent the support structure. 
     Other 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, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1A  is a cross-sectional view of a ceramic cover for an electronic device housing according to one embodiment. 
         FIG. 1B  is a cross-sectional view showing a recess extending into a ceramic cover for the electronic device housing according to one embodiment. 
         FIG. 1C  is a cross-sectional view of an electronic device housing according to one embodiment. 
         FIG. 1D  is a cross-sectional assembly diagram for the electronic device housing shown in  FIG. 1C , according to one embodiment. 
         FIG. 2A  is a cross-sectional view of a ceramic cover for an electronic device housing according to one embodiment. 
         FIG. 2B  is a cross-sectional view showing initial forming of a recess extending into the ceramic cover for the electronic device housing according to one embodiment. 
         FIG. 2C  is a cross-sectional view showing further forming of a recess extending into a ceramic cover for the electronic device housing according to one embodiment. 
         FIG. 2D  is a detailed partial cross-sectional view of the recess shown in  FIG. 2C . 
         FIG. 2E  is a cross-sectional view of an electronic device housing according to one embodiment. 
         FIG. 2F  is a cross-sectional assembly diagram for the electronic device housing shown in  FIG. 2E , according to one embodiment. 
         FIG. 2G  is a detailed partial cross-sectional view showing a peripheral structure housing shown in  FIG. 2F . 
         FIG. 3  is cross-sectional view of an electronic device housing according to another embodiment. 
         FIG. 4  is cross-sectional view of an electronic device housing according to still another embodiment. 
         FIG. 5  is cross-sectional view of an electronic device housing according to yet another embodiment. 
         FIG. 6A  is a cross-sectional view of an electronic device housing according to another embodiment. 
         FIG. 6B  is a cross-sectional assembly diagram for the electronic device housing shown in  FIG. 6A , according to one embodiment. 
         FIG. 6C  is a cross-sectional view of an electronic device housing according to one embodiment. 
         FIG. 7  shows a block diagram of a consumer electronic device according to one embodiment. 
         FIG. 8  is a flow diagram of a housing formation process according to one embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     Embodiments are described herein in the context of a housing for an electronic device. The housing can make use of an outer member, which can be formed of ceramic. The outer member can be aligned, protected and/or secured with respect to other portions of the housing for the electronic device. The electronic device can be portable and in some cases handheld. 
     According to one aspect, an electronic device housing (or enclosure) can be formed from at least one ceramic cover and a peripheral structure formed adjacent the periphery of the ceramic cover. The peripheral structure can be secured adjacent to the ceramic cover with an attachment member. The ceramic cover can include a recess to receive the attachment member. The peripheral structure can be molded adjacent the ceramic cover so that a gapless interface is formed between the peripheral structure and the periphery of the ceramic cover. 
     The following detailed description is illustrative only, and is not intended to be in any way limiting. Other embodiments will readily suggest themselves to skilled persons having the benefit of this disclosure. Reference will now be made in detail to implementations as illustrated in the accompanying drawings. The same reference indicators will generally be used throughout the drawings and the following detailed description to refer to the same or like parts. It should be appreciated that the drawings are generally not drawn to scale, and at least some features of the drawings have been exaggerated for ease of illustration. 
     In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the specific goals, such as compliance with application and business related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure. 
     Embodiments of the invention can relate to apparatus, systems and methods for forming a housing having a thin ceramic member for an electronic device housing. In one example, the ceramic member may be an outer surface of an electronic device housing. The ceramic member may, for example, correspond to a ceramic cover provided at a display area of an electronic device (i.e., situated in front of a display either as a separate part or integrated within the display). Alternatively or additionally, the ceramic member may form a part of the electronic device housing. For example, it may form an outer surface other than for or over the display area. 
     As discussed with reference to the figures, various embodiments may employ a ceramic cover for a top surface of an electronic device enclosure or housing. The ceramic cover may be substantially transparent, and may provide a ceramic cover window, so that a display of electronic device may be viewable through the ceramic cover window. The ceramic cover may have an at least partly crystalline structure. In some embodiment, the ceramic cover may have a substantially crystalline structure. In some embodiment, a majority of the ceramic cover may have a crystalline structure. 
     The ceramic cover may comprise a relatively hard ceramic such as sapphire or zirconia. Indeed, the ceramic cover may be substantially harder than commercial glasses used in mobile telephones. For example, the ceramic cover may have a Vickers hardness that is substantially greater than approximately seven hundred kg/mm 2  (kilograms per square millimeter). The ceramic cover  101  may have a Vickers hardness of approximately two thousand kg/mm 2  or more. The hardness of the ceramic cover may provide advantages in scratch resistance and/or breakage resistance in electronic device enclosures or housings. 
     In addition to being relatively hard, the ceramic cover of the electronic device enclosures or housings as discussed herein may also be relatively strong, while also being made relatively thin. Since thinness in electronic device enclosures or housings may be desirable, it may likewise be desirable for the ceramic cover to be thin. For example, thickness of the ceramic cover may have a thickness of about 0.3-1.0 millimeter. 
     Accordingly, it should be understood that the apparatus, systems and methods for improving strength of thin ceramic are especially suitable for ceramic covers, or displays (e.g., LCD displays), assembled in small form factor electronic devices such as handheld electronic devices (e.g., mobile phones, media players, personal digital assistants, remote controls, etc.). The ceramic can be thin in these small form factor embodiments, such as less than 3 mm, or more particularly between 0.5 and 2.5 mm, or even more particularly between 0.3 and 1.0 mm. The apparatus, systems and methods can also be used for ceramic covers or displays for other devices including, but not limited to including, relatively larger form factor electronic devices (e.g., portable computers, tablet computers, displays, monitors, televisions, etc.). The ceramic can also be thin in these larger form factor embodiments, such as less than 5 mm, or more particularly between 0.5 and 3 mm, or even more particularly between 0.3 and 2.0 mm. 
     In addition to being relatively hard, strong and thin, the ceramic cover may be securely fastened to a peripheral structure of the electronic device enclosure or housing. This may be desirable if the electronic device is accidentally dropped, so that detachment of the ceramic cover from the peripheral structure of the electronic device may be avoided. While adhesives may be used for attachment, there may be the following advantages to using an attachment member, such as a tenon, of the peripheral structure disposed in a laser ablated recess that extends into the ceramic cover. The attachment member may serve to fasten the ceramic cover to the peripheral structure of the electronic device housing more securely than adhesives. Further, use of an adhesive layer to fasten the ceramic cover may add an undesired thickness, which may be substantially avoided by using the attachment member as discussed herein. 
     Additionally, since the strength and hardness of the ceramic cover may create difficulties in machining one or more recesses quickly and easily, such difficulties may be substantially avoided by using laser ablation. In particular, a high power pico second or femto second laser may be used for ablating ceramic cover, which could be formed of sapphire or zirconia. Suitable lasers are available from Manz AG, having a place of business at Steigaeckerstrasse 572768 in Reutlingen, Germany. 
     Embodiments are discussed below with reference to  FIGS. 1A-8 . 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 limited embodiments. 
       FIG. 1A  is a cross-sectional view of a ceramic cover  101  for an electronic device housing according to one embodiment. As shown, the ceramic cover  101  may have a thickness “t” of about 0.3-1.0 millimeter. As shown in  FIGS. 1A-1D , the ceramic cover  101  has a peripheral portion  110 . 
       FIG. 1B  is a cross-sectional view of the ceramic cover  101  according to one embodiment. In this embodiment, the ceramic cover  101  includes one or more recesses  108 A extending into the ceramic cover  101  for the electronic device housing. As shown, the ceramic cover  101  may have one or more laser ablated recesses  108 A extending into the peripheral portion  110  of the ceramic cover  101 . To form the one or more laser ablated recesses  108 A, a fluid jet  138  such as a jet of water  138  may be directed to contact the peripheral portion of the ceramic cover  101 . A laser beam  137  from a laser  139  may be directed within the fluid jet to contact the ceramic cover  101 . The laser beam  137  may laser ablate the recess  108 A which extends into the ceramic cover  101 . The fluid jet  138  may help to speed ablation and make the ablation more productive, and may also cool and carry away ablated ceramic from the recess  108 A. Otherwise, without the fluid jet  138 , hot ablated ceramic may re-deposit within the recess  108 A, which may slow ablation and/or may make ablation less productive. 
       FIG. 10  is a cross-sectional view of an electronic device housing  100  (or electronic device enclosure) according to one embodiment. The electronic device housing  100  may include an outer housing member  101 , which may comprise the ceramic cover  101 , supported and protected by a protective side member  102 , which may comprise a peripheral structure  102 . The protective side member  102  may be positioned tightly adjacent sides of the outer housing member  101 . The protective side members  102  can provide a thin layer of material positioned tightly adjacent sides of the outer housing member  101 , thereby buffering impact at the sides of the outer housing member  101 . The protective side member  102  may also support the outer housing member  101  and may serve to secure the outer housing member  101  to other portions of the electronic device housing  100 . In one embodiment, the protective side member  102  extends around all sides of the outer housing member  101 . In another embodiment, the protective side member  102  extends around those of the sides of the outer housing member  101  that would otherwise be exposed. 
     Accordingly, it should be understood that the ceramic cover  101 , or more generally the outer housing member  101 , may provide a top surface for the electronic device enclosure  100 . The peripheral structure  102  may provide a support surface for the ceramic cover  101  and may provide side protective surfaces for the ceramic cover  101 . 
     As shown in  FIG. 10 , outer housing member  101  can be secured to a support structure  104  of the electronic device housing  100 . The support structure  104  can, for example, be an outer periphery member for the electronic device housing  100 . In one embodiment, the support structure  104  can couple to another outer housing member  106 , which can be formed same or differently than the outer housing member  101 . 
     An attachment member  108  may be coupled with the peripheral portion  110  of the ceramic cover  101 . The ceramic cover  101  may be at least partially secured to peripheral structure  102  the by the attachment member  108 . The attachment member  108 B may comprise a tenon that extends into the recess  108 A of the peripheral portion  110  of the ceramic cover  101 . The recess  108 A may be configured to interlock mechanically with the attachment member  108 B, so as to secure the peripheral portion  110  of the ceramic cover  101  to the peripheral structure  102 . 
     The attachment member  108 B (e.g., tenon) may be made integral with a portion of the peripheral structure  102 . The attachment member  108 B may be molded adjacent the peripheral portion  110  of the ceramic cover  101 . More particularly, the attachment member  108 B may be molded into the recess  108 A of the peripheral portion  110  of the ceramic cover  101 . As shown in  FIG. 1C , molding of the peripheral structure  102  to the peripheral portion  110  of the ceramic cover  101  may provide a substantially gap-free interface between the peripheral structure  102  and edges of the peripheral portion  110  of the ceramic cover  101 . 
     In other words, the protective side member  102  can be secured tightly adjacent the sides of the outer housing member  101  using at least the attachment member  108 B. The protective side member  102  can also be molded in place so as to be tightly adjacent the sides of the outer housing member  101 . By molding the protective side member  102  in place, the outer exposed interface  110  between the sides (e.g., edges) of the outer housing member  101  and the peripheral side member  102  may be essentially gap-free. An internal space  112  is provided internal to the electronic device housing  100  whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. 
     In order to facilitate molding, the peripheral structure  102  may comprise a polymer. Further, the peripheral structure  102  may comprise a polymer strengthened by containing ceramic fibers. The polymer of the peripheral structure  102  may include additives such that coefficient of thermal expansion of the peripheral structure may be made closer to coefficient of thermal expansion of the ceramic cover  101 . The additives may comprise particles or fibers made of ceramic material. 
     The electronic device enclosure  100  may further comprise a support structure  104 , which may be a metal support structure  104 . As shown in  FIG. 1C , the peripheral structure  102  may be formed adjacent to the support structure  104 . The support structure  104  may have at least one feature  105  that may provide a mechanical interlock with the peripheral structure  102  after the peripheral structure  102  has been molded. 
     Accordingly, it should be understood that the various members, parts or assemblies of the electronic device housing  100  can be formed of a variety of materials. In one embodiment, while the outer housing member  101  may be ceramic, the protective side member  102  may be formed from polymer (e.g., thermoplastic), the support structure  104  may be formed from metal or polymer (e.g., plastic), and the another outer housing member  106  may be formed from ceramic, glass, polymer (e.g., plastic) or metal. More particularly, in some embodiments, the protective side member  102  can be a structurally strengthened polymer (e.g., thermoplastic). As an example, the protective side member  102  can be polymer, such as polyarylamide, nylon or polycarbonate, which can be structurally strengthened by including ceramic or glass fibers. For example, some examples of some structurally strengthened polymers include 50% ceramic or glass filled nylon and 30% ceramic or glass filled polycarbonate. 
       FIG. 1D  is a cross-sectional assembly diagram for the electronic device housing  100  shown in  FIG. 1C , according to one embodiment. The outer housing member  101 , which may comprise ceramic cover  101 , may have an outer surface and an inner surface. The inner surface of the ceramic cover  101  may be coupled with the peripheral structure  102 . More specifically, the peripheral portion  110  of the ceramic cover  101  may be coupled with the peripheral structure  102  via the attachment member  108 B. The attachment member  108 B may comprise a tenon for extending into the recess  108 A of the peripheral portion  110  of the ceramic cover  101 , as shown in  FIG. 1D . The recess  108 A may be configured to interlock mechanically with the attachment member  108 B, so as to secure the peripheral portion  110  of the ceramic cover  101  to the peripheral structure  102 . 
     As shown in  FIG. 1D , the attachment member  108 B may be made integral with a portion of the peripheral structure  102 . The attachment member  108 B may be molded to the peripheral portion  110  of the ceramic cover  101 . More particularly, the attachment member  108 B, which may include at least one tenon, may be molded into the recess  108 A of the peripheral portion  110  of the ceramic cover  101 . 
     The protective side member  102  can be molded adjacent the sides of the outer housing member  101 . When the protective side member  102  is molded, the protective side member  102  can also be at least partially formed with the attachment member  108 B within the recess  108 A at the bottom surface of the outer housing member  101 . Moreover, when the protective side member  102  is formed, the protective side member  102  can also be adjacent and secured to an upper side portion of the support structure  104 . When the protective side member  102  is provided at the sides (i.e., edges) of the outer housing member  101 , the protective side member  102  can provide a buffer layer (e.g., bumper), which may dampen impact induced at the sides of the outer housing member  101  of the electronic device housing  100 . 
     For purposes of further illustration,  FIG. 2A  shows a cross-sectional view of a ceramic cover  201  for an electronic device housing according to one embodiment. As shown, the ceramic cover  201  may have a thickness “t” of about 0.3-1.0 millimeter. As shown in  FIGS. 2A-2D , the ceramic cover  201  may have a peripheral portion  210 . 
       FIG. 2B  is a cross-sectional view showing initial forming of a recess extending into the ceramic cover  201  for the electronic device housing according to one embodiment.  FIG. 2B  is a cross-sectional view showing one or more initial recesses  208 AA extending into the ceramic cover  201  for the electronic device housing. More particularly, the ceramic cover  201  may have initial laser ablated recess  208 AA extending into the peripheral portion  210  of the ceramic cover  201 . 
     As shown in  FIG. 2B , a fluid jet  238  such as a jet of water  238  may be directed to contact the ceramic cover  201  at an initial oblique angle. A laser beam  237  from a laser  239  may be directed within the fluid jet  238  to contact the ceramic cover  201  at the initial oblique angle. The laser beam  237  may laser ablate the initial laser ablated recess  208 AA extending into the ceramic cover  201 . 
       FIG. 2C  is a cross-sectional view showing further forming of the recess, so as to provide dovetail recess  208 A extending into the ceramic cover  201  for the electronic device housing according to one embodiment.  FIG. 2C  is a cross-sectional view showing one or more initial dovetail recesses  208 A extending into the ceramic cover  201  for the electronic device housing. More particularly, the ceramic cover  201  may have laser ablated dovetail recess  208 A extending into the peripheral portion  210  of the ceramic cover  201 . 
     As shown in  FIG. 2C , fluid jet  138  may be directed to contact the ceramic cover  201  at an opposite oblique angle, which may be opposite relative to the initial oblique angle as just discussed with respect to  FIG. 2B . The laser beam  237  from the laser  139  may be directed within the fluid jet  238  to contact the ceramic cover  201  at the opposite oblique angle. The laser beam  137  may laser ablate the dovetail recess  208 A extending into the ceramic cover  201 . 
       FIG. 2D  is a detailed partial cross-sectional view of the laser ablated dovetail recess  208 A shown in  FIG. 2C . The laser ablated dovetail recess  208 A shown in detail in  FIG. 2D  may extend into the peripheral portion  210  of the ceramic cover  201  a depth “d” of about 0.3 millimeter. In selecting depth, there may be some compromise between a desire for increasing depth so as to provide increasing strength of the attachment member, and deceasing depth so as to provide for decreasing time spent on laser ablation. 
       FIG. 2E  is a cross-sectional view of an electronic device housing  200  (or electronic device enclosure) according to one embodiment. The electronic device housing  200  may include an outer housing member  201 , which may comprise ceramic cover  201 , supported and protected by a protective side member  202 , which may comprise peripheral structure  202 . The ceramic cover  201 , or more generally the outer housing member  201 , may provide a top surface for the electronic device enclosure  200 . Peripheral structure  202  may provide a support surface for the ceramic cover  201  and may provide side protective surfaces for the ceramic cover  201 . 
     As shown in  FIG. 2E , the peripheral structure  202  may be at least partially secured to the ceramic cover  201  by an attachment member  208 B. The attachment member  208 B may comprise an angled tenon that extends into a dovetail recess  208 A of the peripheral portion  210  of the ceramic cover  201 . The angled tenon may extend at generally opposite angles with respect to each other into the dovetail recess  208 A of the peripheral portion  210  of the ceramic cover  201 . The dovetail recess  208 A may be configured to interlock mechanically with the angled tenon, so as to provide secure attachment for the attachment member  208 B. Moreover, the dovetail recess  208 A may be configured to interlock mechanically with the attachment member  208 B (e.g., angled tenon), so as to securely attach the peripheral portion  210  of the ceramic cover  201  to the peripheral structure  202 . 
     The attachment member  208 B may be made integral with a portion of the peripheral structure  202 . The attachment member  208 B may be molded into the peripheral portion  210  of the ceramic cover  201 . More particularly, the attachment member  208 B may be molded into the dovetail recess  208 A of the peripheral portion  210  of the ceramic cover  201 . An internal space  212  is provided internal to the electronic device housing  200  whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. The peripheral structure may comprise polymer, so as to facilitate molding. 
     The electronic device enclosure  200  may further comprise support structure  204 , which may be a metal support structure. As shown in  FIG. 2E , the peripheral structure  202  may be formed adjacent to the metal support structure  204 . The support structure  204  may have at least one feature  205  that may provide a mechanical interlock with the peripheral structure  202  after the peripheral structure  202  has been molded. 
       FIG. 2F  is a cross-sectional assembly diagram for the electronic device housing  200  shown in  FIG. 2E , according to one embodiment.  FIG. 2F  particularly shows the peripheral structure  202  having the dovetail recess  208 A and the attachment member  208 B (e.g., angled tenon). The outer housing member  201 , which may comprise ceramic cover  201 , may have an outer surface and an inner surface. The inner surface of the ceramic cover  201  may be coupled with the peripheral structure  202 . More particularly, the peripheral portion  210  of the ceramic cover  201  may be coupled with the peripheral structure  202  via the attachment member  208 B and the dovetail recess  208 A. 
     The attachment member  208 B may extend into the dovetail recess  208 A of the peripheral portion  210  of the ceramic cover  201 , as shown in  FIG. 2F . The dovetail recess  208 A may be configured to interlock mechanically with the angled tenon serving as the attachment member  208 B, so as to secure the peripheral portion  210  of the ceramic cover  201  to the peripheral structure  202 . 
     As shown in  FIG. 2F , the attachment member  208 B may be made integral with a portion of the peripheral structure  202 . The attachment member  208 B may be molded to the peripheral portion  210  of the ceramic cover  201 . More particularly, the angled tenon serving as the attachment member  208 B may be molded into the dovetail recess  208 A of the peripheral portion  210  of the ceramic cover  201 . 
       FIG. 2G  is a detailed partial cross-sectional view showing the peripheral structure  202  having the angled tenon for the attachment member  208 B, such as shown in  FIG. 2F . The angled tenon may be part of or formed integral with a portion of the peripheral structure  202 . As shown in  FIG. 2G , the angled tenon serving as the attachment member  208 B may extend at generally opposite angles with respect to each other for engaging the dovetail recess  208 A of the ceramic cover. 
       FIG. 3  is a cross-sectional view of an electronic device housing  300  (electronic device enclosure) according to one embodiment. The electronic device housing  300  may include an outer housing member  301 , which may comprise ceramic cover  301 , supported and protected by a protective side member  302 , which may comprise peripheral structure  302 . The electronic device housing  300  can employ a plurality of tenons for an attachment member  308  engaging a plurality of recesses extending into an inner surface of the ceramic cover  301 . 
     The outer housing member  301 , which may comprise ceramic cover  301 , may have an outer surface in addition to the inner surface. The ceramic cover  301 , or more generally the outer housing member  301 , may provide an outer surface for the electronic device enclosure  300 . The inner surface of the ceramic cover  301  may be coupled with the peripheral structure  302 . More particularly, the peripheral portion  310  of the ceramic cover  301  may be coupled with the peripheral structure  302  via the attachment member  308 . Peripheral structure  302  may provide a support surface for the ceramic cover  301  and may provide side protective surfaces for the ceramic cover  301 . 
     As shown in  FIG. 3 , the peripheral structure  302  may be at least partially secured to the ceramic cover  301  by the attachment member  308 . The attachment member  308  may comprise the plurality of tenons extending into the plurality of recesses of the peripheral portion  310  of the ceramic cover  301 . The plurality of recesses may be configured to interlock mechanically with the plurality of tenons, so as to provide secure attachment of the ceramic cover  301  to the peripheral structure  302 . Moreover, the plurality of recesses may be configured to interlock mechanically with the plurality of tenons of the attachment member  308 , so as to securely attach the peripheral portion  310  of the ceramic cover  301  to the peripheral structure  302 . 
     The plurality of tenons of the attachment member  308  may be made integral with a portion of the peripheral structure  302 . The attachment member  308  may be molded to the peripheral portion  310  of the ceramic cover  301 . More particularly, the plurality of tenons of the attachment member  308  may be molded into the plurality of recesses of the peripheral portion  310  of the ceramic cover  301 . An internal space  312  is provided internal to the electronic device housing  300  whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. The peripheral structure may comprise polymer, so as to facilitate molding. 
     The electronic device enclosure  300  may further comprise support structure  304 , which may be a metal support structure. As shown in  FIG. 3 , the peripheral structure  302  may be formed adjacent to the support structure  304 . The support structure  304  may have at least one feature  305  that may provide a mechanical interlock with the peripheral structure  302  after the peripheral structure  302  has been molded. 
       FIG. 4  is a cross-sectional view of an electronic device housing  400  (electronic device housing) according to one embodiment. The electronic device housing  400  may include an outer housing member  401 , which may comprise ceramic cover  401 , supported and protected by a protective side member  402 , which may comprise peripheral structure  402 . The electronic device housing  300  can employ one or more of tenons for attachment member  408  engaging one or more recesses extending into a side surface of the ceramic cover  401 . 
     The outer housing member  401 , which may comprise ceramic cover  401 , may have an outer surface in addition to the side surface. The ceramic cover  401 , or more generally the outer housing member  401 , may provide an outer surface for the electronic device enclosure  400 . The side surface of the ceramic cover  401  may be coupled with the peripheral structure  402  via the attachment member  408 . The peripheral structure  402  may provide a support surface for the ceramic cover  401  and may provide side protective surfaces for the ceramic cover  401 . 
     As shown in  FIG. 4 , the peripheral structure  402  may be at least partially secured to the ceramic cover  401  by the attachment member  408 . The attachment member  408  may comprises a plurality of tenons extending into a plurality of recesses of the peripheral portion  410  of the ceramic cover  401 . The plurality of recesses may be configured to interlock mechanically with the plurality of tenons, so as to provide secure attachment of the ceramic cover  401  and the peripheral structure  402 . Moreover, the plurality of recesses may be configured to interlock mechanically with the plurality of tenons of the attachment member  408 , so as to securely attach the peripheral portion  410  of the ceramic cover  401  to the peripheral structure  402 . 
     The plurality of tenons of the attachment member  408  may be made integral with a portion of the peripheral structure  402 . The attachment member  408  may be molded to the peripheral portion  410  of the ceramic cover  401 . More particularly, the plurality of tenons of the attachment member  408  may be molded into the plurality of recesses of the peripheral portion  410  of the ceramic cover  401 . An internal space  412  is provided internal to the electronic device housing  400  whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. The peripheral structure may comprise polymer, so as to facilitate molding. 
     The electronic device enclosure  400  may further comprise support structure  404 , which may be a metal support structure. As shown in  FIG. 4 , the peripheral structure  402  may be formed adjacent to the support structure  404 . The support structure  404  may have at least one feature  405  that may provide a mechanical interlock with the peripheral structure  402  after the peripheral structure  402  has been molded. 
       FIG. 5  is a cross-sectional view of an electronic device housing  520  according to one embodiment. The electronic device housing  520  can include a first outer housing member  501 , which may comprise first ceramic cover  501 , supported and protected by a first protective side member  502 . A first protective side member  502  may be positioned tightly adjacent sides of the first outer housing member  501 . The first protective side member  502  may also support the first outer housing member  501  and may serve to secure the first outer housing member  501  to other portions of the electronic device housing  520 . In this embodiment, the first protective side member  502  may be secured to not only the first outer housing member  501  but also a support structure  504 . In addition, in this embodiment, one or more securing features  505  can be provided on an upper surface of housing structure  504 . The support structure  504  may be an outer periphery member for the electronic device housing  520 . 
     The first protective side member  502  can be secured tightly adjacent the sides of the outer housing member  501  with the assistance of a first attachment member  508 . The first attachment member  508  may comprise a first tenon extending into a first recess of peripheral portion  510  of the first ceramic cover  501 . The first recess may be configured to interlock mechanically with the first tenon, so as to provide secure attachment therebetween. Moreover, the first recess may be configured to interlock mechanically with the first tenon of the attachment member  508 , so as to securely attach the peripheral portion  510  of the first ceramic cover  501  to the first peripheral structure  502 . 
     The first protective side member  502  can also be molded in place so as to be tightly adjacent the sides of the first outer housing member  501 . By molding the first protective side member  502  in place, the outer exposed interface  510  between the sides (e.g., edges) of the outer housing member  501  and the peripheral side member  502  is essentially gap-free. 
     The first tenon of the first attachment member  508  may be made integral with a portion of the first peripheral structure  502 . The first attachment member  508  may be molded to the peripheral portion  510  of the first ceramic cover  501 . More particularly, the first tenon of first attachment member  508  may be molded into the first recess of the peripheral portion  510  of the first ceramic cover  501 . The peripheral structure may comprise polymer, so as to facilitate molding. 
     The electronic device housing  520  can also include an internal structure  516  that is integral with or secured to the support structure  504 . In one embodiment, the internal structure  516  can be secured to an inner surface of the support structure  504  such that it is offset from front and back planar boundaries of the support structure  504  (which may be an outer periphery member). As shown in  FIG. 5 , the internal structure  516  can be secured at the mid-point of the height of the support structure  504 . A first internal space  524  may be provided internal to the electronic device housing  520  whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. 
     In this embodiment, the electronic device housing  520  can also include similar structures on an opposite side of the electronic device housing  520 . Namely, the electronic device housing  520  can further include a second outer housing member  526 , which may comprise a second ceramic cover  526 , supported and protected by a second protective side member  528 . The second protective side member  528  can be positioned tightly adjacent sides of the second outer housing member  526 . The second protective side member  528  may also support the second outer housing member  526  and may serve to secure the second outer housing member  526  to other portions of the electronic device housing  520 . In this embodiment, the second protective side member  528  may be secured to not only the second outer housing member  526  but also the support structure  504 . In addition, in this embodiment, one or more securing features  529  can be provided on a bottom surface of the housing structure  504 . The securing features  529  can be integral with the housing structure  504 . As previously noted, the support structure  504  may be an outer periphery member for the electronic device housing  520 . In this embodiment, the second protective side member  528  can be secured to the support structure. 
     The second protective side member  528  can be secured tightly adjacent the sides of the second outer housing member  526  with the assistance of a second attachment member  530 . The second attachment member  530  may comprise a second tenon extending into a second recess of a peripheral portion of the second ceramic cover  526 . The second recess may be configured to interlock mechanically with the second tenon, so as to provide secure attachment therebetween. Moreover, the second recess may be configured to interlock mechanically with the second tenon of the second attachment member  530 , so as to securely attach the peripheral portion of the second ceramic cover  526  to the second peripheral structure  528 . 
     As already mentioned, first internal space  524  may be provided internal to the electronic device housing  520  whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. Further, a second internal space  532  may be provided internal to the electronic device housing  520  (between the internal structure  516  and the second outer housing member  526 ) whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. The second internal space  532  can be separate from or joined with the first internal space  524 . 
     In one embodiment, the first outer housing member  501  can represent a top outer surface for the portable electronic device, and the second outer surface housing  526  can represent a bottom outer surface housing. In one embodiment, one or both the first outer housing member  501  and the second outer housing member  526  are ceramic (e.g., ceramic covers). 
       FIG. 6A  is a cross-sectional view of an electronic device housing  600  according to another embodiment. The electronic device housing  600  includes an outer housing member  601  supported and protected by an inner protective side member  602  and an outer protective side member  603 . The inner protective side member  602  may be positioned tightly adjacent sides of the outer housing member  601 . 
     The inner protective side member  602  can provide a thin layer of material positioned tightly adjacent sides of the outer housing member  601 , thereby buffering impact at the sides of the outer housing member  601 . The outer protective side member  603  may be positioned tightly adjacent the sides of the inner protective side member  602  as well as the sides of the outer housing member  601 . The outer and inner protective side members  602 ,  603  can individually or in combination provide a thin layer of material positioned tightly adjacent sides of the outer housing member  601 , thereby buffering impact at the sides of the outer housing member  601 . One or both of the inner and outer protective side members  602 ,  603  can also support the outer housing member  601  and serve to secure the outer housing member  601 , which may comprise ceramic cover  601 , to other portions of the electronic device housing  600 . 
     As shown in  FIG. 6A , the outer housing member  601  can be secured to a support structure  604  of the electronic device housing  600 . The support structure  604  can, for example, be an outer periphery member for the electronic device housing  600 . In one embodiment, the support structure  604  can couple to another outer housing member  606 , which can be formed differently than the outer housing member  601 . 
     The inner protective side member  602  can be secured tightly adjacent the sides of the outer housing member  601 , which may comprise ceramic cover  601 , using an attachment member  608 . The attachment member  608  may comprise a tenon extending into a recess in the peripheral portion  610  of the ceramic cover  601 . The recess may be configured to interlock mechanically with the tenon, so as to provide secure attachment. Moreover, the recess may be configured to interlock mechanically with the tenon of the attachment member  608 , so as to securely attach the peripheral portion  610  of the ceramic cover  601  to the inner protective side member  602 . 
     The tenon of the attachment member  608  may be made integral with a portion of the inner protective side member  602 . The attachment member  608  may be molded to the peripheral portion  610  of the ceramic cover  601 . More particularly, the tenon of the attachment member  608  may be molded into the recess of the peripheral portion  610  of the ceramic cover  601 . The inner protective side member  602  may comprise polymer, so as to facilitate molding. 
     The attachment member  608  can thus serve to secure the inner protective side member  602  against the sides of the outer housing member  601 . The outer protective side member  603  can be molded in place around at least a portion of the inner protective side member  602  as adjacent at least to a portion of the sides of the outer housing member  601  so as to be tightly adjacent the sides of the outer housing member  601 . By molding the outer protective side member  603  in place, the outer exposed interface  610  between the sides (e.g., edges) of the outer housing member  601  and the outer peripheral side member  603  can be essentially gap-free. During the molding, the outer protective side member  602  can be chemically bonded to at least a portion of the inner protective side member  602 . The outer protective side member  603  may comprise polymer, so as to facilitate molding. An internal space  612  may be provided internal to the electronic device housing  600  whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. 
       FIG. 6B  is a cross-sectional assembly diagram for the electronic device housing  600  shown in  FIG. 6A , according to one embodiment. The outer housing member  601  has a top surface and a bottom surface. The bottom surface of the ceramic cover  601  may be coupled with the inner protective side member  602  via an attachment member  608 B. More particularly, the peripheral portion  610  of the ceramic cover  601  may be coupled with the inner protective side member  602  via the attachment member  608 B. As shown in  FIG. 6B , the attachment member  608 B may comprise a tenon extending into a recess  608 A of the peripheral portion  610  of the ceramic cover  601 . The recess  608 A may be configured to interlock mechanically with the tenon, so as to provide secure attachment for the attachment member  608 B. Moreover, the recess  608 A may be configured to interlock mechanically with the tenon of the attachment member  608 B, so as to securely attach the peripheral portion  610  of the ceramic cover  601  to the inner protective side member  602 . 
     As shown in  FIG. 6B , the tenon of the attachment member  608 B may be made integral with a portion of the inner protective side member  602 . The attachment member  608 B may be molded to the peripheral portion  610  of the ceramic cover  601 . More particularly, the tenon of the attachment member  608 B may be molded into the recess  608 A of the peripheral portion  610  of the ceramic cover  601 . As already mentioned previously, the inner peripheral side member  602  may comprise polymer, so as to facilitate molding. 
     As shown in  FIG. 6B , the inner protective side member  602  can then be secured adjacent the sides of the outer housing member  601 . More particularly, the outer protective side member  603  can be secured to the inner protective side member  602 . The outer protective side member  603  can be molded adjacent at least a portion of the sides of the outer housing member  601  and adjacent or over one or more sides of the inner protective side member  602 . The outer peripheral side member  602  may comprise polymer, so as to facilitate molding. The molding process can also lead to chemical bonding of the outer protective side member  603  and the inner protective side member  602 . 
     Moreover, when the outer protective side member  603  is formed, the outer protective side member  603  can also be adjacent and secured to an upper side portion of the support structure  604 , as shown in  FIG. 6B . When the outer protective side member  603  is provided at the sides (i.e., edges) of the outer housing member  601 , the outer protective side member  603  (alone or in combination with the inner protective side member  602 ) provides a buffer layer (e.g., bumper) that dampens impact induced at the sides of the outer housing member  601  of the electronic device housing  600 . 
       FIG. 6C  is a cross-sectional view of an electronic device housing  620  according to one embodiment. The electronic device housing  620  includes a first outer housing member  601 , which may comprise first ceramic cover  601 , supported and protected by a first inner protective side member  602  and a first outer protective side member  603 . The first inner protective side member  602  is positioned tightly adjacent sides of the first outer housing member  601 . The outer protective side member  603  may be positioned tightly adjacent the sides of the first inner protective side member  602  as well as the sides of the first outer housing member  601 . The first outer and inner protective side members  602 ,  603  can individually or in combination provide a thin layer of material positioned tightly adjacent sides of the first outer housing member  601 , thereby buffering impact at the sides of the first outer housing member  601 . 
     One or both of the first inner and outer protective side members  602 ,  603  can also support the first outer housing member  601  and may serve to secure the first outer housing member  601  to other portions of the electronic device housing  620 . In one embodiment, the first outer protective side member  603  (and possibly also the first inner protective side member  602 ) extends around all sides of the first outer housing member  601 . In another embodiment, the first outer protective side member  603  (and possibly also the first inner protective side member  602 ) extends around those of the sides of the first outer housing member  601  that would otherwise be exposed. 
     The first inner protective side member  602  can be secured tightly adjacent the sides of the first outer housing member  601  using a first attachment member  608 . The first attachment member  608  may comprise a first tenon, which may be formed integral with inner protective side member  602 . The first tenon of the first attachment member  608  may be disposed within a first recess extending into a peripheral portion  610  of ceramic cover  601 . The attachment member  608  can thus serve to secure the first inner protective side member  602  against the sides of the first outer housing member  601 . The first outer protective side member  603  can be molded in place around at least a portion of the first inner protective side member  602  as adjacent at least a portion of the sides of the first outer housing member  601  so as to be tightly adjacent the sides of the outer housing member  601 . By molding the first outer protective side member  603  in place, the outer exposed interface  610  between the sides (e.g., edges) of the first outer housing member  601  and the first outer peripheral side member  603  can be essentially gap-free. During the molding, the first outer protective side member  603  can be chemically bonded to at least a portion of the first inner protective side member  602 . 
     The electronic device housing  620  can also include an internal structure  622  that is integral with or secured to the support structure  604 . In one embodiment, the internal structure  622  can be secured to an inner surface of the support structure  604  such that it is offset from front and back planar boundaries of the support structure  604  (which may be an outer periphery member). As shown in  FIG. 6C , the internal structure  622  can be secured at the mid-point of the height of the support structure  604 . A first internal space  624  is provided internal to the electronic device housing  620  whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. 
     In this embodiment, the electronic device housing  620  can also include similar structures on an opposite side of the electronic device housing  620 . Namely, the electronic device housing  620  can further include a second outer housing member  626  supported and protected by a second inner protective side member  628  and a second outer protective side member  629 . The second inner protective side member  628  can be positioned tightly adjacent sides of the second outer housing member  626 . The second outer protective side member  629  can be positioned tightly adjacent the sides of the inner protective side member  628  as well as the sides of the second outer housing member  626 . The second outer and inner protective side members  628 ,  629  can individually or in combination provide a thin layer of material positioned tightly adjacent sides of the second outer housing member  626 , thereby buffering impact at the sides of the second outer housing member  626 . 
     One or both of the second inner and outer protective side members  628 ,  629  can also support the second outer housing member  626  and serve to secure the second outer housing member  626  to other portions of the electronic device housing  620 . In one embodiment, the second outer protective side member  629  (and possibly also the inner protective side member  628 ) extends around all sides of the second outer housing member  626 . In another embodiment, the second outer protective side member  629  (and possibly also the second inner protective side member  628 ) extends around those of the sides of the second outer housing member  626  that would otherwise be exposed. 
     The second inner protective side member  628  can be secured tightly adjacent the sides of the second outer housing member  626  using a second attachment member  630 . The second attachment member  630  may comprise a second tenon, which may be formed integral with second inner protective side member  628 . The second tenon of the second attachment member  630  may be disposed within a second recess extending into a peripheral portion of the second ceramic cover  626 . 
     The attachment member  630  can thus serve to secure the second inner protective side member  628  against the sides of the second outer housing member  626 . The second outer protective side member  629  can be molded in place around at least a portion of the second inner protective side member  628  and adjacent to at least a portion of the sides of the second outer housing member  626  so as to be tightly adjacent the sides of the second outer housing member  626 . By molding the second outer protective side member  629  in place, the outer exposed interface  631  between the sides (e.g., edges) of the second outer housing member  626  and the second outer peripheral side member  629  can be essentially gap-free. During the molding, the second outer protective side member  629  can be chemically bonded to at least a portion of the second inner protective side member  628 . 
     As already mentioned, first internal space  624  may be provided internal to the electronic device housing  600  whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. Further, a second internal space  632  is provided internal to the electronic device housing  620  (between the internal structure  622  and the second outer housing member  626 ) whereby various electrical components can be attached, affixed or placed so as to provide electronic operations for the electronic device. The second internal space  632  can be separate from or joined with the first internal space  624 . 
     In one embodiment, the first outer housing member  601  can represent a top outer surface for the portable electronic device, and the second outer surface housing  626  can represent a bottom outer surface housing. In one embodiment, both the first outer housing member  601  and the second outer housing member  626  are ceramic (e.g., ceramic covers). 
       FIG. 7  shows a block diagram of a consumer electronic device  700  according to one embodiment. The consumer electronic device  700  may comprise a ceramic cover  701  for a top surface for the consumer electronic device  700 . The ceramic cover  701  may comprises at least one of sapphire and zirconia. The ceramic cover  701  may have a laser ablated recess  708 A extending into the ceramic cover  701 . 
     The consumer electronic device  700  may further comprise a peripheral structure  702  for providing a support surface for the ceramic cover  701  and for providing side protective surfaces for the ceramic cover  701 . The peripheral structure  702  may be at least partially secured to the ceramic cover  701 . 
     The consumer electronic device  700  may further comprise electrical components, which may include at least a controller  732 . Controller  732  may be coupled with a memory  736  and a display  734 . The display may be provided at or adjacent the top surface for the consumer electronic device  700 . The ceramic cover  701  may be provided over the display  734 . 
     The consumer electronic device  700  may be one of a media player, a media storage device, a portable digital assistant, a tablet personal computer, a computer, a mobile phone (e.g., cellular phone), a smart phone, a global positioning system unit, and a remote control. At least a portion of functionality for the foregoing may be provided by the controller  732  being coupled with suitable additional electronic components  738 . 
       FIG. 8  is a flow diagram of a housing formation process  800  according to one embodiment of the invention. The housing formation process  800  can operate to produce a housing for an electronic device, or at least a portion of such a housing. 
     The housing formation process  800  can initially obtain  802  a ceramic member. The ceramic member can have a top surface and a bottom surface, wherein the top surface may provide an outer surface for substantially all of a surface of the electronic device. More generally, the ceramic member may serve as a significant outer surface for the housing. For example, the ceramic member can correspond to a top surface for the housing. Alternatively or additionally, the ceramic member can correspond to a bottom surface for the housing. 
     The ceramic member is typically thin, particularly when used with portable electronic devices. In one embodiment, the ceramic member has a thickness of less than 5 mm, or more particularly less than 1 mm. The ceramic member may comprise a relatively hard ceramic such as sapphire or zirconia. The ceramic member may be substantially transparent, and may provide a ceramic window, so that a display of electronic device may be viewable through the ceramic window. The ceramic member may have an at least partly crystalline structure. The ceramic member may have a substantially crystalline structure. A majority of the ceramic member may have a crystalline structure. 
     After the ceramic member has been obtained  802 , a recess may be laser ablated  804  into the ceramic member. A fluid jet may be directed to contact the ceramic member, and a laser beam may be directed within the fluid jet to contact the ceramic member, so as to laser ablate a recess extending into the ceramic member. In some embodiments, a plurality of recesses may be laser ablated into the ceramic member. 
     The recess can have any of a variety of configurations. For example, the recess can include one or more undercuts. In one embodiment, the recess can be configured as a dovetail recess. The dovetail recess may be laser ablated into the ceramic member. A laser beam may be directed to contact the ceramic member at one or more oblique angles, so as to laser ablate the dovetail recess extending into the ceramic member. 
     Thereafter, the ceramic member can be aligned  806  relative to a support structure. The support structure can be provided as being a component of the housing for the electronic device. For example, the support can pertain to a side structure for the housing or an interior support member. As an example, the support structure may comprise metal. 
     After the ceramic member has been aligned  806  with the support structure, a peripheral protective side portion can be molded  808  adjacent the periphery of the ceramic member and/or adjacent the recess and/or adjacent the support structure. In particular, molding  808  may comprise injecting molding material (e.g., polymer) into the recess extending into the ceramic member. 
     Furthermore, handling of the ceramic member for which a component (e.g., peripheral side member) is being formed around may be facilitated by using a coating during a molding process. A metal mold may normally be used in molding. However, the metal mold may otherwise introduce handling difficulties for a ceramic member during molding. To mitigate handling difficulties for the ceramic member, the metal mold (i.e., its inner surfaces) can be coated. The coating can, for example, be a thin layer of polytetrafluoroethylene (PTFE) or polyimide film. 
     Accordingly, it should be understood that molding  808  may comprise obtaining a metal mold having an inner surface configured to form the peripheral protective side portion for the electronic device, coating al least a portion of the inner surface of the metal mold, and/or injecting a molding material (e.g., polymer) into the metal mold to form the peripheral protective side portion for the electronic device. 
     The molded peripheral side portion may be secured  810  or at least partially secured to the ceramic member via an attachment member. The attachment member may comprise a tenon extending into the recess of a peripheral portion of the ceramic cover. The recess may be configured to interlock mechanically with the tenon, so as to provide secure attachment therebetween. Moreover, the recess may be configured to interlock mechanically with the tenon of the attachment member, so as to securely attach the peripheral portion of the ceramic cover to the molded peripheral side portion. The attachment member may be formed as a ring or a substantial portion of a ring about the peripheral portion of the ceramic cover. 
     The tenon of the attachment member may be made integral with the molded peripheral side portion. More particularly, the tenon of the attachment member may be molded into the recess of the ceramic cover, as the molded peripheral side portion is molded against the ceramic cover. 
     Furthermore, the molded peripheral side portion may be formed adjacent to a support structure. The molded peripheral side portion may be secured to the support structure via at least one mechanical feature of the support structure. The support structure can, for example, be formed of metal. 
     Once the molded peripheral side portion is secured  810  to the ceramic member, the housing formation process  800  can end. 
     The protective side members discussed above are typically thin layers of material positioned tightly adjacent sides of the outer housing member, thereby buffering impact at the sides of the outer housing members. In one embodiment, the protective side members are to be strong; hence, a structurally strengthened polymer, such as polyarylamide, can be utilized. The polyarylamide can be strengthened by containing ceramic or glass fibers. One source of strengthened polyarylamide is IXEF polyarylamide (PARA) from Solvay Advanced Polymers, L.L.C which can contain glass fiber reinforcement. 
     Additionally, since the protective side members are tightly adjacent sides of the outer housing member, the respective materials used for the protective side members and the outer housing member. Specifically, the Coefficient of Thermal Expansion (CTE) of the respective materials, if not controlled, can produce undesired stress on the sides of the outer housing member. Plastics tend to have CTE&#39;s (e.g., roughly 100 millimeters/meter/° C.) that are dramatically higher than that of ceramics such as sapphire or zirconia, some manufactured polymers, such as polyarylamide, can have CTE&#39;s (e.g., roughly 30 millimeters/meter/° C.) that are substantially closer to that of sapphire or zirconia and thereby would, if used, induce less stress on the sides of the outer housing member. For example, in one embodiment, a manufactured polymer for such use could have a CTE less than or equal to about 50 millimeters/meter/° C., and in another embodiment, a manufactured polymer for such use could have a CTE less than or equal to about 35 millimeters/meter/° C. In one implementation, additive can be added to a polymer so to bring is CTE closer to that of ceramics such as sapphire or zirconia. As examples, the additives can be particles or fibers, which can be formed from glass or ceramic. Also, as noted above, the thickness of the protective side member can be thin, for example, the thickness can be on the order of about 1 mm or less in one embodiment. 
     In still other embodiments, the protective side materials can be formed from multiple materials that can be alternated, intertwined or layered. The later of material against the edges of the outer housing member of ceramic can have a CTE relatively close to that of ceramic such as sapphire or zirconia, while an outer layer can have a higher CTE can permit a greater range of material, such as polymers (e.g., plastics). 
     The protective side members are able to be thin yet be cosmetically unintrusive. For example, in some embodiments, the thickness (t 1 ) for the protective side member can be less than 1 mm (e.g., 0.8 mm). Also, in some embodiments, the thickness (t 2 ) of the outer housing member can be less than 5 mm (e.g., 1 mm). However, these thicknesses are exemplary and vary with the size of the electronic device housing and with desired strength. Using a strengthened material for the protective side members as noted above can also be advantageous. Nevertheless, the provisioning of thin protective side members for outer housing members, such as ceramic covers, facilitates providing portable electronic device housings that are compact and thin yet resistant to side impact damage to the outer housing members. 
     Additional details on side protective members for electronic device housings are contained in U.S. application Ser. No. 12/794,563, filed Jun. 4, 2010, and entitled “OFFSET CONTROL FOR ASSEMBLING AN ELECTRONIC DEVICE HOUSING,” and in U.S. application Ser. No. 12/944,671, filed Nov. 11, 2010, and entitled “INSERT MOLDING AROUND GLASS MEMBERS FOR PORTABLE ELECTRONIC DEVICES” which are hereby incorporated herein by reference. 
     In general, the steps associated with the methods of the present invention may vary widely. Steps may be added, removed, altered, combined, and reordered without departing from the spirit or the scope of the present invention. 
     The various aspects, features, embodiments or implementations of the invention described above may be used alone or in various combinations. 
     While this specification contains many specifics, these should not be construed as limitations on the scope of the disclosure or of what may be claimed, but rather as descriptions of features specific to particular embodiment of the disclosure. Certain features that are described in the context of separate embodiments may also be implemented in combination. Conversely, various features that are described in the context of a single embodiment may also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. 
     While embodiments and applications have been shown and described, it would be apparent to those skilled in the art having the benefit of this disclosure that many more modifications than mentioned above are possible without departing from the inventive concepts herein.

Metadata:
Filing Date: 20130508
Publication Date: 20180116
Grant Date: 20180116
Priority Date: 20130508
Inventors: KWONG KELVIN
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/185", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49002", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/185", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49002", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 51864618