PATENT DOCUMENT

Publication Number: US-9989992-B2
Application Number: US-201514832976-A
Country: US
Kind Code: B2

Title: Logo features of a portable computer

Abstract:
An enclosure for a portable computing device is disclosed. The enclosure includes an indicium (e.g., logo) positioned in an opening extending partially through the enclosure. The enclosure includes multiple material removal processes. First, a tool (e.g., laser ablation tool) can be used to ablate the opening defining an ablation having a shape or profile similar to that of the indicium. A second material removal process can remove a region within the ablation to define an indicium support. The second material removal process may be performed by a CNC cutting tool capable of forming the indicium support to a desired precision. As a result, when the indicium is secured with the indicium support, the indicium includes a desired flatness that prevents an undesired reflectivity. In order to ensure the indicium properly fits in the opening, a third material removal process may be performed to define an indention region around the opening.

Claims:
What is claimed is: 
     
       1. An enclosure of a portable computing device, comprising:
 a substrate including an exterior region and an opening extending partially through the substrate to define a blind hole; 
 an indicium support disposed in the blind hole at a first depth measured from the exterior region to a top surface of the indicium support; 
 a relief section in the blind hole, the relief section extending around the indicium support and disposed at a second depth measured from the exterior region to a surface of the relief section, the second depth greater than the first depth; and 
 an indicium received within the blind hole and overlapping the relief section to define an air gap below the indicium. 
 
     
     
       2. The enclosure of  claim 1 , wherein the indicium is adhesively secured with the indicium support. 
     
     
       3. The enclosure of  claim 1 , wherein the indicium support includes a size and a shape such that the indicium is co-planar with respect to the exterior region of the substrate. 
     
     
       4. The enclosure of  claim 1 , wherein:
 the blind hole is at least partially defined by a sidewall extending from the exterior region to the surface of the relief section and having an indention region formed therein. 
 
     
     
       5. The enclosure of  claim 4 , wherein the relief section includes a darkened region on the surface of the relief section, wherein the darkened region extends partially into the indention region. 
     
     
       6. The enclosure of  claim 1 , wherein the substrate comprises a tapered region. 
     
     
       7. A method for incorporating an indicium within a substrate used for an enclosure of a portable computing device, the method comprising:
 forming a blind hole that extends partially through the substrate and having a size and shape in accordance with the indicium, the blind hole formed by removing a first amount of the substrate to a first depth and by removing a second amount of the substrate to form a relief section to a second depth greater than the first depth, wherein: 
 the relief section defines an indicium support configured to support the indicium; and 
 a portion of the indicium overlaps the relief section to define an air filled space between the portion of the indicium and the relief section. 
 
     
     
       8. The method of  claim 7 , further comprising means for forming a darkened region in the relief section such that the relief section includes an appearance darker than an appearance of the substrate. 
     
     
       9. The method of  claim 8 , further comprising adhesively securing the indicium to the indicium support. 
     
     
       10. The method of  claim 8 , wherein the means for forming the darkened region is selected from a group consisting of burning a surface of the relief section, applying an ink to the surface of the relief section, and applying a paint to the surface of the relief section. 
     
     
       11. The method of  claim 9 , wherein when the indicium is adhesively secured with the indicium support, the first depth allows the indicium received by the indicium support to be co-planar with respect to an exterior region of the substrate. 
     
     
       12. The method of  claim 7 , further comprising forming an indention region in the blind hole proximate to the relief section. 
     
     
       13. The method of  claim 7 , wherein forming the blind hole comprises cutting the substrate along the indicium support in a circular path from an outer region of the indicium support to a central region of the indicium support. 
     
     
       14. A housing for carrying an operational component of a portable computing device, the housing comprising:
 an exterior region having a surface; 
 a recessed portion that extends partially through the housing, the recessed portion comprising a terminus surface and a wall extending from the terminus surface and into a cavity defined by the recessed portion, the wall defining a size and shape of a support structure, the wall further comprising an edge that defines a size and shape of a support surface of the support structure such that the support surface is approximately parallel to the surface of the exterior region; and 
 a generally flat object positioned in the recessed portion and supported by the support structure such that a portion of the object extends beyond the edge to define an air clap between a bottom surface of the object and the recessed portion. 
 
     
     
       15. The housing of  claim 14 , wherein the wall and the terminus surface define a relief section that assures that a viewable surface of the object secured to the support structure at the support surface is generally co-planar with the exterior region. 
     
     
       16. The housing of  claim 15 , wherein when a lateral dimension of the object is greater than that of the support structure, the relief section allows the portion of the object to extend past the support structure without interference thereby (i) maintaining co-planarity of the object with respect to the support surface and (ii) maintaining the viewable surface of the object parallel with the exterior region. 
     
     
       17. The housing of  claim 14 , wherein the support surface is formed using an additive manufacturing process by depositing material at the terminus surface or formed by attaching a pre-formed support structure at the terminus surface. 
     
     
       18. The housing of  claim 14 , further comprising a second wall extending from the terminus surface having a corresponding edge that defines a boundary between the exterior region and the recessed portion. 
     
     
       19. The housing of  claim 18 , wherein a contour of the object defines a size and shape of the corresponding edge. 
     
     
       20. The housing of  claim 14 , wherein an exterior surface of the generally flat object is substantially coplanar with the surface of the exterior region.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/104,597, filed on Jan. 16, 2015, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The described embodiments relate generally to a portable computing device. In particular, the present embodiments relate to securing an indicium to the portable computing device. 
     BACKGROUND 
     Portable computing devices often carry a logo or some other identifying feature secured to an exterior region (e.g., an enclosure) of the portable computing device. In some cases, the logo is formed from translucent material such that a light source within the portable computing device emits light that passes through the logo thereby illuminating the logo. However, the light source draws electrical current from an internal power supply (e.g., battery) of the portable computing device. In cases where the portable computing device is not electrically connected to an electrical outlet, the portable computing device may incur reduced operating times due to electrical current consumed by the light source. 
     SUMMARY 
     In one aspect, an enclosure of a portable computing device is described. The enclosure may include a substrate including an exterior region and an opening extending partially through the substrate to define a blind hole. The enclosure may further include an indicium support in the blind hole. In some cases, the indicium support is disposed at a first depth measured from the exterior region to a top surface of the indicium support. The enclosure may further include a relief section in the blind hole. In some cases, the relief section extends around the indicium support and is disposed at a second depth measured from the exterior region to a surface of the relief section. Also, the second depth may be greater than the first depth. 
     In another aspect, a method for forming an enclosure of a portable computing device is described. The method may include forming a blind hole that extends partially through the substrate and having a size and shape in accordance with the indicium. In some embodiments, the blind hole may be formed by removing a first amount of the substrate to a first depth and a second amount of the substrate to form a relief section to a second depth greater than the first depth. In some embodiments, a size and shape of the relief section defines an indicium support configured to receive the indicium. 
     In another aspect, a housing for carrying an operational component of a portable computing device is described. The housing may include an exterior region having a surface. The housing may further include a recessed portion that extends partially′ through the housing. The recessed portion may include a terminus surface and a wall extending from the terminus surface and into a cavity defined by the recessed portion. The wall may define a size and shape of a support structure tier supporting an object. Also, the wall may further include an edge that defines a size and shape of a support surface of the support structure such that the support surface is approximately parallel to the surface of the exterior region. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       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. 1  illustrates an isometric view of an embodiment of a portable computing device in an open configuration; 
         FIG. 2  illustrates an isometric view of the embodiment shown in  FIG. 1 , with the portable computing device in a closed configuration; 
         FIG. 3  illustrates an isometric view of an alternate embodiment of a portable computing device in an open configuration; 
         FIG. 4  illustrates an isometric view of the embodiment shown in  FIG. 3 , with the portable computing device in a closed configuration; 
         FIG. 5  illustrates a plan view of an embodiment of a display housing that includes several openings, in accordance with the described embodiments; 
         FIG. 6  illustrates a plan view of an alternate embodiment of a display housing that includes a first opening having an indicium support defined by a round feature; 
         FIG. 7  illustrates a plan view of an alternate embodiment of a display housing that includes a first opening having an indicium support defined by a ring feature; 
         FIG. 8  illustrates a plan view of an alternate embodiment of a display housing that includes a first opening having an indicium support defined by several round features; 
         FIG. 9  illustrates a cross sectional view of a substrate, in accordance with the described embodiments; 
         FIG. 10  illustrates plan view of the embodiment of the substrate shown in  FIG. 9 ; 
         FIG. 11  illustrates a cross sectional view of an embodiment of a substrate undergoing a material removal process; 
         FIG. 12  illustrates a cross sectional view of the substrate shown in  FIG. 11 , with the substrate undergoing an additional material removal process; 
         FIG. 13  illustrates a cross sectional view of the substrate shown in  FIG. 12 , with an in indicium secured with the indicium support; 
         FIG. 14  illustrates a cross sectional view of the substrate shown in  FIG. 12 , with the substrate undergoing an additional material removal process; 
         FIG. 15  illustrates a cross sectional view of the substrate shown in  FIG. 14 , with the relief section having a darkened region; 
         FIG. 16  illustrates a cross sectional view of the substrate shown in  FIG. 15 , with an in indicium secured with the indicium support; 
         FIG. 17  illustrates a cross sectional view of a substrate having an alternate embodiment of an indicium with a chamfered region, in accordance with the described embodiments; 
         FIG. 18  illustrates a cross sectional view of an embodiment of a substrate having an indicium support having undergone an initial material removal process, in accordance with the described embodiments; 
         FIG. 19  illustrates plan view of the indicium support shown in  FIG. 18  after the initial material removal process; 
         FIG. 20  illustrates a cross sectional view of the substrate shown in  FIG. 18 , with the indicium support undergoing a partial material removal process; 
         FIG. 21  illustrates plan view of the indicium support shown in  FIG. 20 ; 
         FIG. 22  illustrates a cross sectional view of the substrate shown in  FIG. 20 , with the indicium support further undergoing the subsequent material removal process; 
         FIG. 23  illustrates plan view of the indicium support shown in  FIG. 22 ; 
         FIG. 24  illustrates a cross sectional view of the substrate shown in  FIG. 22 , with the indicium support further undergoing the subsequent material removal process such that the indicium support reaches its final shape; 
         FIG. 25  illustrates plan view of the indicium support shown in  FIG. 23 ; 
         FIG. 26  illustrates a plan view of an interior portion of a top case of a portable computing device having undergone a material removal process, in accordance with the described embodiments; 
         FIG. 27  illustrates a plan view of an exterior region of a bottom case of a portable computing device having undergone a material removal process, in accordance with the described embodiments; and 
         FIG. 28  illustrates a flow chart showing a method for forming an enclosure of a portable computing device, in accordance with the described embodiments. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein. 
     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. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The following disclosure relates to an enclosure of a portable computing device. In particular, the disclosure relates to manufacturing processes to a substrate (e.g., display housing that encloses a visual display) such that the substrate receives an indicium (e.g., logo) in a desired manner. Traditional portable computing devices may include an opening extending completely through the substrate, with an indicium positioned within the opening. The indicium may be formed from a translucent material (e.g., plastic) allowing a light source of the portable computing device to illuminate the indicium. 
     However, the following disclosure relates to portable computing devices that include a substrate (e.g., display housing) having an indicium, some of which are not illuminated by the portable computing device. This may be due in part to several reasons. For instance, the light source previously described may be removed in order to conserve battery power and/or to increase volume within the portable computing device. Also, the indicium may be positioned at least partially within a blind hole of the substrate. The phrase “blind hole” as used throughout this detailed description and in the claims refers to an opening or cavity that extends partially, but not completely, through a substrate. In this manner, a substrate may include a first region (or first surface) having a blind hole visible when viewing the first region. The substrate may also include a second region (or second surface) opposite the first region such that when viewing the second surface the blind hole is not visible. 
     The blind hole may include several features designed to enhance the position and appearance of the indicium. For instance, a material removal process may remove a portion of the substrate to include a size and a shape similar to that of the indicium. However, it will be appreciated that the material removal process may form a profile of the blind hole slightly larger (e.g., 1 millimeter or less in diameter) than that of the indicium such that the indicium may be positioned within the blind hole. A cutting tool or other material removal tool, such as a laser ablation tool, may be used to remove the material of the substrate. The cutting tool may remove additional material in order to define a relief section in the substrate. The relief section allows for some machining error, defect, or tolerance without altering the positioning of the indicium. The relief section may allow increased tolerances in a material removal operation, which may reduce manufacturing time and/or reduced waste as the substrate is less likely to be discarded due to the increased tolerances. 
     Within the blind hole, the substrate may undergo an additional material removal process. In some cases, an additional cutting tool (e.g., computer number control, or CNC, tool) may be used to remove an additional portion of the substrate to define an indicium support. The indicium support may be a base or platform used to receive and support an indicium defined as a logo, word, symbol, and/or letter. Modern cutting tools allow for high precision cutting such that the indicium support is relatively flat. For example, a substrate undergoing the described material removal process in mass production can nonetheless include an indicium support having a flatness measuring 15 micrometers. In other words, the variation from one edge of the indicium support to another edge of the indicium support may vary in elevation or topography by 15 micrometers or less. In this manner, an indicium secured with the indicium support also appears relatively flat. 
     Other material removal features may be performed on the substrate. For instance, an additional material removal process may define indention region disposed around the indicium support and the blind hole. The indention region can be designed to open to the blind hole and allow for some variance in the size and shape of the indicium. In this manner, an outer region (e.g., tapered region) of the blind hole does not unnecessarily engage or interfere with the positioning of the indicium. Also, the relief section and/or the indention region may be darkened by, for example, laser darkening or adding ink. In this manner, when the indicium is secured with the indicium support, a gap between the blind hole and the indicium allows only minimal, if any, visibility behind the indicium. 
     These and other embodiments are discussed below with reference to  FIGS. 1-28 . 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. 1  illustrates an isometric view of an embodiment of a portable computing device  100  in an open configuration. In some embodiments, the portable computing device  100  is a laptop computing device made by Apple, Inc., of Cupertino, Calif. As shown, the portable computing device  100  includes an enclosure  102  that includes a display housing  104  that receives a display panel  106  capable of displaying visual content. A lower portion  108  of the enclosure  102  may include a top case  110  coupled with a bottom case (not shown). The top case  10  includes several openings to receive a keyboard  112 . The top case  110  and the bottom case may enclose several internal components (e.g., memory, processors, batteries, etc.). In some embodiments, the display housing  104 , the top case  110 , and the bottom case are formed from plastic. In the embodiment shown in  FIG. 1 , the display housing  104 , the top case  110 , and the bottom case are formed from a metal (e.g., aluminum, steel, stainless steel). 
       FIG. 2  illustrates an isometric view of the embodiment of the portable computing device  100  shown in  FIG. 1 , with the portable computing device  100  in a closed configuration. As shown, the display housing  104  may further include an indicium  114 . In some embodiments, the indicium  114  is a letter, or multiple letters. In other embodiments, the indicium  114  is a symbol. In the embodiment shown in  FIG. 2 , the indicium  114  is a logo. In some instances, the logo represents a manufacturer of the portable computing device  100 . Other shapes or features, including shapes having three or more sides, can be represented by the indicium  114 . Also, in some embodiments, the indicium  114  is made from aluminum. In other embodiments, the indicium  114  is made from plastic. In the embodiment shown in  FIG. 2 , the indicium  114  is made from stainless steel. Also, in some embodiments, the indicium  114  may include a first indicium portion  116  and a second indicium portion  118  that define the indicium  114 . However, in other embodiments, the indicium  114  is defined by a single structure. 
       FIGS. 3 and 4  illustrate an isometric view of an alternate embodiment of a portable computing device  200  in an open and closed configuration, respectively. As shown, the portable computing device  200  includes a top case  210  that includes several features similar to those of the top case  110  shown in  FIGS. 1 and 2 . However, the top case  210  in  FIGS. 3 and 4  includes a tapered region. In other words, the thickness of the top case varies from opposite ends of the top case  210 . For example, the first region  212  of the top case  210  includes a first thickness and the second region  214  of the top case  210  includes a second region  214  having a second thickness less than the first thickness. Accordingly,  FIGS. 3 and 4  illustrate the top case  210  tapering from the first region  212  to the second region  214 . In this manner, the portable computing device  200  includes less volume and material which may correspond to a portable computing device having less weight than traditional portable computing devices. 
       FIG. 5  illustrates a plan view of an embodiment of a display housing  304  that includes several openings, in accordance with the described embodiments. In some embodiments, the display housing  304  is formed from aluminum. As shown, the display housing  304  includes a first opening  312  and a second opening  314 . The first opening  312  and the second opening  314  may combine to receive an indicium (such as the indicium  114  shown in  FIG. 2 ). In some embodiments, the first opening  312  and the second opening  314  are formed from a cutting process. In the embodiment shown in  FIG. 5 , a profile  322  (i.e., a size and a shape) of the first opening  312  and a profile  324  of the second opening  314  are formed from laser ablation. Additional material removal processes may include other cutting tools, and will be discussed below. Using the laser ablation tool to form the profile includes several advantages. For instance, the enlarged view illustrates the first opening  312  having an edge feature  316 . The laser ablation tool is capable of forming the edge feature  316  with a smaller radius, and accordingly, forming the first opening  312  in a desired manner which more closely resembles the shape of the indicium. For purposes of comparison, the dotted lines  326  in the enlarged view proximate to the edge feature  316  illustrate define an edge feature formed using a cutting tool other than the laser ablation tool. As shown, the edge feature defined by the dotted lines  326  includes a larger and more rounded radius than that of the edge feature  316 . Accordingly, the edge feature  316 , formed by a laser ablation tool, includes a sharper edge and more closely resembles a size and a shape of an indicium. 
     Although the indicium support  318  shown in  FIG. 5  includes a size and a shape similar to that of an indicium, the first opening  312  may include an indicium support  318  that receives the indicium. The indicium support  318  may undergo a material removal process such that the indicium support  318  is sub-flush (i.e., below) with respect to an exterior region or surface of the display housing  304 . In some embodiments, the indicium support  318  includes a shape similar to that of the indicium to be secured with the indicium support  318 . Also, in some embodiments, the indicium support  318  includes a smaller surface area than that of the indicium. The smaller surface area of the indicium support  318  may require less precision machining to form the indicium support  318 , which may lead to less manufacturing time. Also, due to the relatively small size and shape of the second opening  314 , an indicium support is not required for a portion of the indicium positioned in the second opening  314 , the laser ablation process used to form the second opening  314  is sufficient to receive a portion of the indicium and other cutting or ablating techniques may not be required. 
     The indicium support used to secure the indicium with the display housing may be formed with other shapes and sizes. For example,  FIG. 6  illustrates a plan view of an alternate embodiment of a display housing  404  that includes a first opening  412  having an indicium support  418  defined by a round feature. The indicium support  418  may require even less material removal than that of the indicium support  318  (shown in  FIG. 5 ).  FIG. 7  illustrates a plan view of an alternate embodiment of a display housing  444  that includes a first opening  452  having an indicium support  458  defined by a ring feature that includes a reduces support structure or support surface. Accordingly, a region  462  internal with respect to the indicium support  458  is also sub-flush with respect to the indicium support  458 . This allows for an indicium support  458  with an even smaller surface area which requires less material removal.  FIG. 8  illustrates a plan view of an alternate embodiment of a display housing  484  that includes a first opening  492  having an indicium support  498  defined by several round features disposed within the first opening  492 . Although the features are shown as rounded, in other embodiments, the indicium support  498  includes several features that may include three or more sides to each feature. 
     A substrate used as part of an enclosure may include several features designed to an enhance not only the appearance of the substrate but also enhance the disposal of a feature, such as an indicium (not shown), on or in the substrate. The features may provide for a consistent, repeatable process desirable in mass production of portable computing devices. The following embodiment in  FIGS. 9 and 10  describe relationships among several features of a substrate  604  suitable for use with a portable electronic device. For purposes of simplicity, only a portion of the substrate  604  is shown. However, the size and shape of the substrate  604  may be similar to, for example, the display housing  104  or the top case  110  shown in  FIG. 1 . In this manner, the substrate  604  may be designed to carry one or more operational components, such as a display panel  106  (shown in  FIG. 1 ). 
       FIG. 9  illustrates a cross sectional view  600  of a portion of a housing in the form of substrate  604 , the housing used to carry an operational component of a portable electronic device in accordance with the described embodiments. As shown, the substrate  604  may include an exterior region  606  having a surface  608  associated with a cosmetic appearance of the housing viewable by a user of the portable electronic device. Moreover, during manufacturing, the substrate  604  may undergo material removal by way of a machining operation using, for example, a cutting tool or a laser ablation tool to define a recessed portion  610 . In the described embodiment, the recessed portion  610  extends only partially through the substrate  604  and as such may also be referred to as a blind hole. Also, the exterior region  606  and the surface  608  extend circumferentially around the recessed portion  610 . 
     The recessed portion  610  can include a bottom portion referred to as a terminus region having a terminus surface  612  and a wall  614  that extends from the terminus surface  612  having an edge  616  that defines a boundary between the surface  608  and the recessed portion  610 . In some embodiments, a wall  618  extending into the recessed portion  610  from the terminus surface  612  has an edge  620  that together define a support structure  622  having a support surface  624  used to support an object. The support surface  624  may be designed to support an indicium or other object. It should be noted that the support structure  622  can be integrally formed with substrate  604  using the same or a similar machining operation that formed the recessed portion  610  subsequently followed by planarization of the support surface  624 . The support structure  622  can also be formed subsequent to the formation of the recessed portion  610 . For example, the support structure  622  can be formed using an additive manufacturing process (such as depositing metal using a solid state deposition process above over an imaginary line  628  extending along the terminus surface  612  followed by a machining operation to define the support structure  622 ). The support structure  622  can also be pre-formed and attached or otherwise secured to the terminus surface  612 . In any case, the planarity of the support surface  624  can be such that the support surface  624  is generally parallel with respect to the surface  608  of the exterior region  606 . In this way, the support structure  622  is able to receive and support a generally flat object in such a way that a viewable surface of the object is also generally parallel with respect to the surface  608 . Further, a thickness of the object and that of the support structure  622  may combine to render the visible surface of the object (when secured with and supported by the support structure  622 ), co-planar with respect to the surface  608 . 
     It should be noted that since the support structure  622  extends into the recessed portion  610 , the terminus surface  612  can cooperate with the wall  614  and the wall  618  to define a relief section  626  that assures that an outer surface of an object (such as an indicium) secured to the support structure  622  at the support surface  624  is co-planar with the surface  608 . In this way, a relief section  626  can allow a lateral dimension of the object to be larger than that of the support structure  622  and therefore can overhang, or extend beyond the edge  620 . In the described embodiment, the relief section  626  can be formed using the machining operation used to form the recessed portion  610  and as a result of forming the support structure  622 , or can be formed or otherwise modified subsequent to the formation of the support structure  622 . The relief section  626  can be formed in such a way as to partially surround the support structure  622  or to fully surround support structure  622 . 
       FIG. 10  illustrates plan view of the embodiment of the substrate  604  shown in  FIG. 9 . In some embodiments, the support surface  624  of the support structure  622  is defined by one or more edges features similar to, for example, the edge feature  316  (shown in  FIG. 5 ). In the embodiment shown in  FIG. 10 , the support structure  622  and the support surface  624  takes on a circular shape. It should be noted, however, that the support structure  622  and support surface  624  may take on various shapes and sizes. It should be further noted, that the edge  616  can define a shape substantially similar to that of an indicium or indicium disposed on and secured at the support surface  624 . Also, a single cutting and/or ablating operation of the recessed portion  610  (shown in  FIG. 9 ) may simultaneously form the edge  616  and the edge  620 . For example, a laser ablation tool that removes material from the substrate  604  can form both the edge  616  and the edge  620  such that the edge  616  and the edge  620  are parallel to each other, as shown in  FIG. 10 . Also, in some cases, the relief section  626  may also be co-formed with the edge  616  and the edge  620 . 
       FIG. 11  illustrates a cross sectional view of an embodiment of a substrate  704  undergoing a material removal process. In some embodiments, the substrate  704  is a display housing of a portable computing device, such as the display housing  304  shown in  FIG. 5 . A cutting tool  750  used to remove material from the substrate  704 . In some embodiments, the cutting tool  750  is a laser ablation tool that uses a laser beam  752 . The cutting tool  750  removes a portion of the substrate  704  to define a profile having a size and a shape similar that of an indicium (such as a first indicium portion  116 , shown in  FIG. 2 ). In other words, the cutting tool  750  traces a desired shape around along an exterior region  706  of the substrate  704 . 
       FIG. 12  illustrates a cross sectional view of the substrate  704  shown in  FIG. 11 , with the substrate  704  undergoing an additional material removal process. As shown, a second cutting tool  770  is used to remove an additional portion of the substrate  704  to define an indicium support  718 . In some embodiments, the second cutting tool  770  is a rotary tool, such as a CNC cutting tool. The indicium support  718  can be used as a platform that receives an indicium (not shown). The indicium support  718  may be sub-flush with respect to the exterior region  706 . Further, the indicium support  718  is sub-flush to a first depth  732  measured from the exterior region  706  to a top surface  722  of the indicium support  718 . Generally, the first depth  732  is defined by a dimension approximately similar to a thickness of the indicium and a thickness of the securing means (e.g., adhesive, solder, weld) between the indicium and the indicium support  718 . In this manner, the indicium, when installed with the securing means, may be co-planar with respect to the exterior region  706  of the substrate  704 . In some embodiments, the first depth  732  is less than 1 millimeter. Further, in some embodiments, the first depth  732  is less than 0.5 millimeters. 
     The material removed by using the cutting tool  750  and the second cutting tool  770  define a blind hole  730  extending partially through the substrate  704 . Generally, when an indicium is not positioned within the substrate  704 , the blind hole  730  is visible only when viewing the exterior region  706 . 
     Also, at least some of removed material from the cutting tool  750  (in  FIG. 9 ) is sub-flush with respect to the indicium support  718 . This area is defined as a relief section  724  that extends around the indicium support  718 . The relief section  724  is located at a second depth  734  greater than the first depth  732 . The second depth  734  is measured from the exterior region  706  to a surface  728  of the relief section  724 . In some cases, the cutting tool  750  may not remove all of the desired material, and a protrusion  712  may remain. However, because the cutting tool  750  removes material of the substrate  704  to the second depth  734 , an indicium positioned on the indicium support  718  is not disturbed by the protrusion. Thus, the relief section  724  provides a clearance to an indicium as the relief section  724  may accommodate defects, such as the protrusion  712 , which reduces the required precision of the cutting tool  750  which may lead to reduced manufacturing times. 
     The laser ablation technique offers further advantages. For example, by removing material from the substrate  704  with a laser cutting tool, the laser cutting tool defines a surface area of the indicium support  718  that is less than that of the indicium. The reduced surface area of the indicium support  718  offers a smaller surface area for the second cutting tool  770  to cut, which may improve the control of the second cutting tool  770 . In other words, the cutting accuracy of the second cutting tool  770  may increases with less surface area to be cut by the second cutting tool  770 . 
       FIG. 13  illustrates a cross sectional view of the substrate  704  shown in  FIG. 12 , with an in indicium  714  secured with the indicium support  718 . The indicium  714  may be secured with the indicium support  718  via an adhesive layer  742 . In some embodiments, the adhesive layer  742  is a pressure sensitive adhesive (“PSA”). However, other securing means may be used in other embodiments, which may include any adhesive generally known in the art for securing together two or more metallic structures. While the adhesive layer  742  shown in  FIG. 11  is positioned between the indicium  714  and the indicium support  718 , in other embodiments, the void or space between the indicium  714  and the blind hole of the substrate  704  is filled with an adhesive. For example, in some embodiments, the relief section  724  (shown in  FIG. 10 ) is filled with an adhesive. 
     Also, the exterior region  706  of the substrate  704  may be separated from an exterior region  716  of the indicium  714  by a distance defined by a gap  736 . It will be appreciated that the gap  736  extends around the outer perimeter of the exterior region  716 . In some embodiments, the gap  736  is 1 millimeter or less. Further, in some embodiments, the gap  736  is approximately 0.1 millimeters. 
     As shown in the enlarged view, the profile formed via the cutting tool  750  (shown in  FIG. 11 ) forms a tapered region  744 . This is due in part to the laser beam  752  (also shown in  FIG. 11 ) having a tapered, non-vertical region. The tapered region  744  may be inclined at an angle  772  with respect to an imaginary vertical line  774  extending from the exterior region  706  of the substrate  704 . The angle  772  is approximately in the range of 5 to 15 degrees. The indicium  714  selected may be formed within a specified tolerance. Accordingly, in some cases, an interior region  726  of the indicium  714  may contact the tapered region  744 . As a result, the positioning of the indicium  714  is altered in an undesired manner. 
       FIG. 14  illustrates a cross sectional view of the substrate  704  shown in  FIG. 12 , with the substrate  704  undergoing an additional material removal process. For purposes of illustration, the indicium  714  and adhesive layer  742  shown in  FIG. 13  have been removed. In order to provide additional clearance for an indicium, a third cutting tool  780  may be used to remove additional material from the substrate  704 . In some embodiments, the third cutting tool  780  a rotary tool, such as a T-cutting tool. The material removal process performed by the third cutting tool  780  defines an indention region  746  in the substrate  704 . As shown, the indention region  746  extends around the blind hole  730  and opening to the blind hole  730 . The indention region  746  ensures an indicium will not be disturbed, or contacted, by the tapered region  744  of the substrate  704 . 
       FIG. 15  illustrates a cross sectional view of the substrate  704  shown in  FIG. 14 , with the relief section  724  having a darkened region  748 . Several means may be used to form the darkened region  748 . For example, in some embodiments, the darkened region  748  is formed from a laser tool (not shown) that burns or chars a surface  728  of the relief section  724 . In other embodiments, the darkened region  748  is formed by applying an ink, which may be brushed or printed onto the surface  728 . Still, in other embodiments, the darkened region  748  is formed by applying a paint to the surface  728 . Also, as shown, the darkened region  748  may extend at least partially into the indention region  746 . Generally, the darkened region  748  includes a color or appearance darker than a color or appearance of the substrate  704  (which may be a color, such as gray). The darkened region  748  is intended to at least partially disguise any surface (e.g., surface  728  of the relief section  724 ) below the indicium (when assembled). Also, similar to the relief section  724 , the darkened region  748  may extend around the indicium support  718 . 
       FIG. 16  illustrates a cross sectional view of the substrate shown in  FIG. 15 , with an in indicium  714  secured with the indicium support  718 , in a location defined by the blind hole  730  (shown in  FIG. 14 ). As shown, the indicium  714  is secured with the indicium support  718  via the adhesive layer  742 . Also, the indention region  746  ensures the indicium  714  is not disturbed by the tapered region  744  of the substrate  704 . Further, the darkened region  748  disguises the surface  728  of the relief section  724  (depicted in  FIG. 15 ) as well as a portion of the indention region  746 . In this manner, a user viewing the indicium  714  may not be able to view the surface  728  through the gap  736 . 
     The indicium support  718  of the substrate  704  is generally flat. That is, the indicium support  718  is generally parallel to the exterior region  706  of the substrate  704 . This ensures the indicium, when secured with the indicium support, is also flat. In order to ensure the indicium support is flat, the cutting tool (for example, the second cutting tool  770  shown in  FIG. 12 ) may include certain cutting techniques. 
     In order to select the indicium  714  for the indicium support  718 , the area of the blind hole may be measure subsequent to the cutting techniques previously described. Then, the indicium  714  may be an indicium selected from one or more bins, with each bin having multiple indicia sorted by size. For example, the bins may include a first bin may include an indicia of a first size and a second bin including indicia of a second size different from the first size. An indicium may be selected from the first bin or the second bin based upon the area of the blind hole. The selected indicium may include a size that not only provides minimizes a gap between the indicium and the blind hole, but also a consistent gap size between the indicium and the blind hole. 
     Some of the various features shown and described in  FIGS. 13-17  may also be incorporated in the embodiment shown in  FIGS. 9 and 10 . For example, in some embodiments, the substrate  604  shown in  FIGS. 9 and 10  includes a tapered region  744 , an indention region  746 , and/or a darkened region  748 . 
       FIG. 17  illustrates a cross sectional view of a substrate  754  having an alternate embodiment of an indicium  764  with a chamfered region  766 , in accordance with the described embodiments. As shown, the indicium  764  may be adhesively secured (via an adhesive layer  792 ) to the substrate  754  in a manner previously described. The chamfered region  766  provides additional clearance between the indicium  764  and the tapered region  794  of the substrate  754 , thereby improving the likelihood of the indicium  764  positioned in a desired manner. Although an indention region  796  is shown, in other embodiments, the indention region  796  is removed as the chamfered region  766  provides sufficient clearance between structures. Accordingly, the chamfered region  766  may reduce the required number of manufacturing steps performed on the substrate  754 . Also, the chamfered region  766  may be incorporated in previously described embodiments of an indicium. 
       FIGS. 18-25  illustrate a processing for cutting a substrate  804  in a manner that defines an indicium support  818 , in accordance with the described embodiments. The cutting process designed herein may be prevent unwanted characteristics, such as warping of the indicium support  818 .  FIG. 18  illustrates a cross sectional view of an embodiment of a substrate  804  having an indicium support  818  having undergone an initial material removal process, in accordance with the described embodiments. The initial material removal process of the indicium support  818  is intended to be a “rough” cut, and is designed to remove only a portion of the substrate  804 . A subsequent material removal process to the indicium support  818  increases the depth of the indicium support  818  respect to the exterior region  806  of the substrate  804 . When an indicium and securing means (e.g., adhesive, weld, solder) are applied to the indicium support  818 , the indicium is approximately co-planar, or flush, with respect to the exterior region  806  of the substrate  804 . 
       FIG. 19  illustrates plan view of the indicium support  818  shown in  FIG. 18  after the initial material removal process. The indicium support  818  includes a relatively flat surface designed to receive an indicium. In order to achieve a desired co-planarity, which in some cases is approximately 10 micrometers across the surface of the indicium support  818 , additional cutting techniques described below may be used. 
       FIG. 20  illustrates a cross sectional view of the substrate  804  shown in  FIG. 18 , with the indicium support  818  undergoing the subsequent material removal process. During the subsequent material removal process, a cutting tool  870  (e.g., CNC cutting tool) traverses along a surface of the indicium support  818 . For example, as shown in  FIG. 18 , the cutting tool  870  may begin by cutting an outer region  824  of the indicium support  818  to define a circular cutting path that ends in a central region  822  of the indicium support  818 . 
       FIG. 21  illustrates plan view of the indicium support  818  shown in  FIG. 20 . In some embodiments, the cutting pattern is a linear path (e.g., raster path). In other embodiments, the cutting path is a circular path beginning at a central region  822  of the indicium support  818  and ending at an outer region  824  of the indicium support  818 . Still, in other embodiments, the cutting path is a “zig zag” path along the indicium support  818 . In the embodiment shown in  FIG. 19 , the cutting path is a circular path beginning along the outer region  824  and traversing in a direction toward the central region  822 . 
       FIG. 22  illustrates a cross sectional view of the substrate  804  shown in  FIG. 20 , with the indicium support  818  further undergoing the subsequent material removal process.  FIG. 23  illustrates plan view of the indicium support  818  shown in  FIG. 22 .  FIGS. 22 and 23  show the cutting tool  870  removing additional material from the indicium support  818  as the cutting tool  870  continues traversing in a direction toward the central region  822 . 
       FIG. 24  illustrates a cross sectional view of the substrate shown in  FIG. 22 , with the indicium support  818  further undergoing the subsequent material removal process such that the indicium support  818  reaches its final shape. The indicium support  818  is now sub-flush with respect to the exterior region  806  at a depth such that an indicium  814 , secured with the indicium support  818  via an adhesive layer  842 , is co-planar with respect to the exterior region  806 . The cutting pattern used form the subsequent material removal process of the indicium support  818  can form an indicium support  818  having a flatness of 15 micrometers. In other words, the variation from one edge of the indicium support  818  to another edge of the indicium support  818  may vary in elevation or topography by 15 micrometers or less. In this manner, an indicium  814  secured with the indicium support  818  also appears relatively flat. It will be appreciated that features shown in other embodiments—such as a laser-ablated profile, an indention feature, and/or a darkened region—may also be performed to the substrate  804  prior to securing the indicium  814  with the substrate  804 . 
       FIG. 25  illustrates plan view of the indicium support  818  shown in  FIG. 24 . For purposes of illustration, the indicium  814  (shown in  FIG. 24 ) is removed to show a surface of the indicium support  818 . As shown, the cutting pattern is complete when the cutting tool (not shown) reaches the central region  822 . This allows the indicium support  818  to include a desired co-planarity of the surface of indicium support  818 . 
     The laser ablation process used to form a profile in a substrate may be used in other applications on a portable computing device. For example,  FIG. 26  illustrates a plan view of an interior portion  920  of a top case  910  of a portable computing device (e.g., portable computing device  200  shown in  FIG. 3 ) having undergone a material removal process, in accordance with the described embodiments. As shown, the top case  910  includes an outer peripheral region  930 . Within the outer peripheral region  930 , the top case  910  further includes an ablation region  940  defined by a material removal process from a laser ablation tool previously described. The ablation region  940  extends around the top case  910  adjacent to, and within, the outer peripheral region  930 . The ablation region  940  may be designed to receive a bottom case (not shown) such that the top case  910  and the bottom case combine to receive some internal components of the portable computing device. 
       FIG. 27  illustrates a plan view of an exterior region  950  of a bottom case  960  of a portable computing device having undergone a material removal process, in accordance with the described embodiment. As shown, the bottom case  960  may include a first foot receiving region  962 , a second foot receiving region  964 , a third foot receiving region  966 , and a fourth foot receiving region  968 . Each of these foot receiving regions may be designed to receive, for example, an injection-molded structure defining a foot designed to engage a surface on which a portable computing device lies. Also, the outer region of each of these foot receive regions may be formed by a laser ablation process previously described. Also, the bottom case  960  may be secured with the top case  910  (shown in  FIG. 26 ). 
       FIG. 28  illustrates a flowchart  1000  showing a method for forming an enclosure of a portable computing device, in accordance with the described embodiments. In step  1002 , a blind hole is formed that extends partially through the substrate. The blind may include a size and shape in accordance with the indicium. For example, the blind hole may include one or more edge features such that the blind hole includes a profile similar to that of the indicium. Also, the blind hole may be formed by removing a first amount of the substrate to a first depth and by removing a second amount of the substrate to form a relief section to a second depth greater than the first depth. The removal means may include a cutting tool, such as a CNC tool, as well as an ablation tool, such as a laser ablation tool. Also, in some embodiments, a size and shape of the relief section defines an indicium support configured to receive the indicium. The relief section may be disposed at a depth different than that of the indicium support. For example, the relief section may be disposed at a depth greater than that of the indicium support, with the depth measured from an exterior region or surface of the substrate. 
     The indicia (multiple indicium) described in this detailed description may be formed in different sizes and/or different thicknesses within a specified tolerance. Then, the indicia may be separated into different bins according to their size and/or thickness. Once the material removal processes previously described are performed on a substrate, a vision system may inspect the substrate, and in particular, features such as the blind hole and the indicium support. The vision system may input the inspection to controller. Based upon the size and shape of the blind hole and/or indicium support, the controller determine from which bin an indicium will be selected, and directs a robotic arm to select an indicium from the selected bin. This process allows for a best fit between an indicium and a substrate, which corresponds to a portable computing device having a more consistent appearance. 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     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 targeted 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: 20150821
Publication Date: 20180605
Grant Date: 20180605
Priority Date: 20150116
Inventors: FARAHANI, HOUTAN R.
WU, HSINHAN
CORBET, LINDSAY D.
KWAN, HILBERT T.
SPRIGGS, KATHERINE
TAN, You Fu
Assignee: APPLE INC
CPC Classifications: [{"code": "G09F7/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": true, "tree": "[]"}, {"code": "G09F7/16", "inventive": true, "first": true, "tree": "[]"}, {"code": "G09F7/16", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1616", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1616", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 56407849