PATENT DOCUMENT

Publication Number: US-9787345-B2
Application Number: US-201414230324-A
Country: US
Kind Code: B2

Title: Laser welding of transparent and opaque materials

Abstract:
Welding of transparent material in electronic devices. An electronic device may include an enclosure having at least one aperture formed through a portion of the enclosure. The electronic device may also include a component positioned within the aperture formed through the portion of the enclosure. The component may be laser welded to the aperture formed through the enclosure. Additionally, the component may include transparent material. A method for securing a component within an electronic device may include providing an electronic device enclosure including at least one aperture, and positioning a component within the aperture formed through the enclosure. The component positioned within the aperture may include a transparent material. The method may also include welding the component to the electronic device enclosure.

Claims:
We claim: 
     
       1. An apparatus, comprising:
 an enclosure having a first melting temperature, comprising:
 an exterior surface; 
 an interior surface opposite the exterior surface; and 
 a sidewall extending between the exterior and interior surfaces and defining an aperture; 
 
 a transparent component positioned within the aperture and having a second melting temperature that is greater than the first melting temperature and having a first surface and a second surface opposite the first surface connected by a side surface defining an edge having at least one surface defect, wherein the at least one surface defect is the result of a forming process of the transparent component comprising a crack or depression; and 
 a laser weld formed between the sidewall of the enclosure and the edge of the transparent component and encircling the transparent component within the aperture, the laser weld generated by passing a laser beam onto the sidewall to heat the sidewall to a temperature that is greater than first melting temperature and less than the second melting temperature, wherein 
 the laser weld includes a portion of the enclosure filling the at least one surface defect of the transparent component. 
 
     
     
       2. The apparatus of  claim 1 , wherein the enclosure comprises at least one of:
 sapphire; 
 metal; 
 glass; or 
 plastic. 
 
     
     
       3. The apparatus of  claim 1 , wherein the transparent component comprises at least one of:
 sapphire; 
 glass; or 
 plastic. 
 
     
     
       4. The apparatus of  claim 1 , wherein a size of the aperture at the interior surface of the enclosure is greater than a size of the aperture at the exterior surface. 
     
     
       5. The apparatus of  claim 1 , wherein the sidewall includes a bezel portion. 
     
     
       6. The apparatus of  claim 1 , wherein the sidewall is angled and the edge is beveled. 
     
     
       7. The apparatus of  claim 1 , wherein the first and/or second surfaces of the transparent component is/are treated. 
     
     
       8. The apparatus of  claim 1 , wherein the aperture is substantially circular. 
     
     
       9. The apparatus of  claim 1 , wherein the transparent component includes at least one of:
 a button 
 a transparent layer for a display; or 
 a window for a camera system. 
 
     
     
       10. The apparatus of  claim 1 , wherein the transparent component forms at least a portion of an exterior surface of an electronic device. 
     
     
       11. A method for forming an apparatus comprising:
 providing an enclosure having a first melting temperature, the enclosure comprising:
 an exterior surface; 
 an interior surface opposite the exterior surface; and 
 a sidewall extending between the exterior and interior surfaces and defining an aperture; 
 
 positioning a transparent component having a second melting temperature that is greater than the first melting temperature within the aperture, the transparent component having a first surface and a second surface opposite the first surface connected by a side surface defining an edge having at least one surface defect, wherein the at least one surface defect is the result of a forming process of the transparent component comprising a crack or depression; and 
 forming a laser weld between the sidewall of the enclosure and the edge of the transparent component that encircles the transparent component within the aperture, the laser weld is generated by a laser beam heating the sidewall to a temperature that is greater than first melting temperature and less than the second melting temperature, wherein 
 the laser weld includes a portion of the aperture filling the at least one surface defect of the transparent component. 
 
     
     
       12. The method of  claim 11 , further comprising:
 surface treating a first surface of the transparent component; and 
 surface treating a second surface of the transparent component opposite the first surface. 
 
     
     
       13. The method of  claim 12 , wherein the positioning comprises aligning the treated first surface of the transparent component and the exterior surface of the enclosure. 
     
     
       14. The method of  claim 11 , further comprising:
 prior to the positioning of the component within the aperture, applying an adhesive to at least one of:
 the aperture; or 
 the window. 
 
 
     
     
       15. The method of  claim 11 , wherein
 the forming process comprises at least one of:
 cutting; or 
 shaping. 
 
 
     
     
       16. The method of  claim 11 , wherein the laser weld is generated by passing a laser beam through the transparent component onto the sidewall. 
     
     
       17. An apparatus, comprising:
 an enclosure having a first melting temperature, comprising:
 an exterior surface; 
 an interior surface; and 
 a sidewall formed on interior surface defining an aperture; 
 
 a transparent component positioned within the aperture and having a second melting temperature that is greater than the first melting temperature and having a first surface and a second surface opposite the first surface connected by a side surface defining an edge having at least one surface defect, wherein the at least one surface defect is the result of a forming process of the transparent component comprising a crack or depression; and 
 a laser weld formed between the sidewall of the enclosure and the edge of the transparent component and encircling the transparent component within the aperture, the laser weld is generated by a laser beam heating the sidewall to a temperature that is greater than first melting temperature and less than the second melting temperature, wherein 
 the laser weld includes a portion of the enclosure filling the at least one surface defect of the transparent component.

Description:
TECHNICAL FIELD 
     The disclosure relates generally to electronic devices, and more particularly to transparent materials included in electronic devices and methods for securing transparent materials in electronic devices. 
     BACKGROUND 
     Conventional electronic devices typically include a plurality of working or functional components all included within a single housing or casing. These components allow a user to interact with the electronic device. Some components of the electronic device include, for example, buttons, switches, screen displays and cameras. Each of these components may include portions that are visible or exposed on an outer surface of the electronic device, and may interact or may be in communication with portions of the component located within the electronic device. For example, the button may include a contact portion positioned on the outer surface of the electronic device, and may be in communication with internal portions that may interact with the electronic device and/or distinct components (e.g., processor) of the electronic device. In another example, a display and/or camera may include transparent windows that protect the components, but allow the components to be seen/be exposed to the exterior of the electronic device. 
     The components of the electronic device that are visible or exposed on an outer surface of the electronic device are typically coupled directly to the housing or include windows coupled directly to the housing. For example, the button may include a casing portion that is directly coupled to the housing, and the camera may include a window, positioned adjacent a camera lens, coupled directly to the housing. The components of the electronic device are typically coupled to the housing using an adhesive. More specifically, an adhesive is typically dispensed between the component and the housing to couple the component to the housing of the electronic device, and/or maintain the component within the housing during the operational life of the electronic device. 
     The reliance on adhesive alone to couple the components to the housing of the electronic device may cause operational issues. For example, over the operational life of the electronic device, the adhesive may wear or weaken. This may cause the component (e.g., button) or portions of the component (e.g., camera window) to become displaced or uncoupled from the housing of the electronic device. When the components become displaced or uncoupled from the housing, the electronic device may not function as intended or may not function at all. 
     In addition, the reliance on adhesive alone to couple the components to the housing of the electronic device may cause manufacturing issues. That is, when using adhesive to couple the components to the housing, it is typically required that the contact surfaces be treated in order to ensure adequate contact. More specifically, the contact surfaces of the component and the portion of the housing receiving the component may be planed, polished, and/or resurfaced in order to provide substantially flat contact surfaces free of defects formed during prior processing of the component (e.g., cutting, shaping). The treatment step of the contact surfaces adds time to the process of manufacturing the electronic device, especially, when the contact surfaces need to be treated multiple times and/or undergo multiple treatment processes. 
     These defects may be reduced, or eliminated, by providing additional cutting or shaping processes during the manufacturing of the components. However, these additional cutting or shaping processes tend to add time to the overall manufacturing process and, dependent on the material of the component, can increase cost as well. For example, where the component is made from corundum, commonly referred to as sapphire, additional cutting processes can be performed on the component to minimize the defects on the contact surface. However, because of sapphires hardness (e.g., 9.0 Mohs hardness scale), cutting the material can be difficult, time consuming and can result in rapid wear to the cutting tool. This rapid wear to the cutting tool may result in constant replacement and/or sharpening of the cutting tool during the manufacturing process. 
     The inclusion of adhesive to couple to the components to the housing of the electronic device may increase the cost of manufacturing based on the amount of adhesive used and/or the number of components that utilize adhesive within the electronic device. That is, the adhesive itself adds an additional component to the electronic device, which also increases the cost to manufacture the electronic device, and increases the manufacture time by the amount of time it takes to apply the adhesive to the component and/or the housing of the electronic device. 
     Additionally, the inclusion of adhesive to couple the components to the housing of the electronic device may require further processes in order to meet cosmetic requirements for the electronic device. For example, after adhesive is applied to couple components of the electronic device, a decorative ink may be applied to the electronic device to hide the adhesive between the components. That is, a decorative ink may be applied to a surface and/or component of the electronic device to substantially hide the adhesive, which may not be aesthetically or visually appealing. Similar to the adhesive above, the application of the decorative ink on an electronic device may increase the manufacturing time of the electronic device, as well as, increase the cost of manufacturing the electronic device. 
     SUMMARY 
     Generally, embodiments discussed herein are related to apparatuses including transparent materials, transparent materials used in electronic devices and methods for securing transparent materials in electronic devices. The apparatuses and electronic devices typically include two components: a first component (e.g., enclosure) having an aperture, and a second component which includes the transparent material. The second component is positioned within the aperture of the first component and is laser welded directly to the first component. More specifically, a laser is positioned above the first and second component and emits a beam through the second component, including the transparent material, to the first component to form a laser weld between the respective components. By welding the first component to the second component, the need for an adhesive to bind the components is unnecessary, and a substantially permanent coupling may be formed between the components. Additionally, in some embodiments, by forming the laser weld between the first and second component by emitting a laser beam through the second component, the weld may be substantially hidden from the user of the electronic device. That is, by laser welding the respective components, the weld may be substantial undetectable by, or concealed from, the user of the electronic device. Not only will the laser weld improve the coupling strength between the first and second component, but it may also improve the cosmetic features of the electronic device. 
     One embodiment may include an apparatus. The apparatus may include a first component including an aperture, and a second component including a transparent material. The second component may be positioned within the aperture of the first component. Additionally, the second component may be welded to the first component. 
     Another embodiment may include an electronic device. The electronic device may include an enclosure. The enclosure of the electronic device may include at least one aperture formed through a portion of the enclosure. Additionally, the electronic device may include a component positioned within the at least one aperture formed through the portion of the enclosure. The component may be laser welded to the at least one aperture formed through the portion of the enclosure. Furthermore, the component may include a transparent material. 
     A further embodiment may include a method for securing a component within an electronic device enclosure. The method may include providing an electronic device enclosure. The electronic device enclosure may include at least one aperture. The method may also include positioning a component within the at least one aperture formed through the enclosure, and welding the component to the enclosure. The component may include a transparent material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1A  shows an illustrative front view of an electronic device, according to embodiments. 
         FIG. 1B  shows an illustrative back view of the electronic device of  FIG. 1A , according to embodiments. 
         FIG. 2A  shows an exploded, front cross-section view of a portion of electronic device of  FIG. 1B  taken along line  2 - 2  of  FIG. 1B , according to embodiments. 
         FIG. 2B  shows an enlarged portion of a window of electronic device as depicted in  FIG. 2A , according to embodiments. 
         FIG. 2C  shows a front cross-section view of a portion of electronic device of  FIG. 1B  taken along line  2 - 2 , according to embodiments. 
         FIG. 2D  shows an enlarged portion of a window and enclosure of electronic device as depicted in  FIG. 2D , according to embodiments. 
         FIG. 3  shows a front cross-section view of a portion of electronic device of  FIG. 1A  taken along line  3 - 3  of  FIG. 1A , according to embodiments. 
         FIG. 4  shows a front cross-section view of a portion of electronic device of  FIG. 1A  taken along line  4 - 4  of  FIG. 1A , according to embodiments. 
         FIG. 5  shows a flow chart illustrating a method for securing a component within an electronic device enclosure. 
         FIGS. 6A-6D  show illustrative views of a portion of an electronic device, including a window and an enclosure, undergoing processes of securing as depicted in  FIG. 5 , according to embodiments. 
     
    
    
     It is noted that the drawings of the invention are not necessarily to scale. The drawings are intended to depict only typical aspects of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     The following disclosure relates generally to electronic devices, and more particularly, to transparent materials included in electronic devices and methods for securing transparent materials in electronic devices. 
     Discussed herein are apparatuses including transparent materials, transparent materials used in electronic devices and methods for securing transparent materials in electronic devices. The apparatuses and electronic devices typically include two components: a first component (one example of which is an enclosure) having an aperture; and a second component which includes the transparent material. The second component is positioned within the aperture of the first component and is laser welded directly to the first component. 
     More specifically, a laser is positioned above the first and second component and emits a beam through the second component, including the transparent material, to the first component to form a laser weld between the respective components. By welding the first component to the second component, the need for an adhesive to bind the components may be unnecessary, and a substantially permanent coupling may be formed between the components. Additionally, in some embodiments, by forming the laser weld between the first and second component by emitting a laser beam through the second component, the weld may be substantially hidden from the user of the electronic device. That is, by laser welding the respective components, the weld may be substantially undetectable by, or concealed from, the user of the electronic device. Not only may the laser weld improve the coupling strength between the first and second component, but it may also improve the cosmetic features of the electronic device. 
     These and other embodiments are discussed below with reference to  FIGS. 1A-6D . 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. 
       FIGS. 1A and 1B  show an illustrative front and back view, respectively, of an electronic device  100 , according to embodiments. In the illustrated embodiment, electronic device  100  is implemented as a mobile phone. Electronic device  100  may include, or may be connected to a biometric sensing device (not shown). Other embodiments can implement the electronic device  100  differently, such as, for example, as a laptop or desktop computer, a tablet computing device, a gaming device, a display, a digital music player, a wearable computing device or display such as a watch or glasses, and other types of electronic devices that can receive biometric data from a biometric sensing device. 
     Electronic device  100  may include an enclosure  102  at least partially surrounding a display  104  and one or more buttons  106  or input devices. The enclosure  102  may form an outer surface or partial outer surface and protective case for the internal components of the electronic device  100 , and may at least partially surround the display  104 . The enclosure  102  may be formed of one or more components operably connected together, such as a front piece and a back piece. In a non-limiting example, where enclosure  102  may be formed from a plurality of components, enclosure  102  may include a trim piece that may be coupled to additional components configured to be operably connected to form a protective case for electronic device  100 , as discussed herein. Alternatively, the enclosure  102  may be formed of a single piece operably connected to the display  104 . Enclosure  102  may include a plurality of distinct materials including, but not limited to: corundum, commonly referred to as sapphire, metal, glass or plastic. Additionally, enclosure  102  may include a decorative and/or coating layer that be disposed on the outer and/or or inner surface of enclosure  102 . The decorative layer and/or coating layer may be disposed on the surface(s) of enclosure  102  to protect the enclosure and/or provide a decorative feature (e.g., exterior color) for electronic device  100 . 
     Display  104  may be implemented with any suitable technology, including, but not limited to, a multi-touch sensing touchscreen that uses liquid crystal display (LCD) technology, light emitting diode (LED) technology, organic light-emitting display (OLED) technology, organic electroluminescence (OEL) technology, or another type of display technology. Display  104  may include a substantially transparent layer  108  positioned above the touchscreen. That is, and as discussed herein, transparent layer  108  may be positioned above the touchscreen of display  104  and may be positioned within an aperture of enclosure  102 , such that enclosure  102  and transparent layer  108  are in planar alignment with front surface  112  of electronic device  100 . Transparent layer  108  may protect display  104  from containments, without obstructing a user&#39;s view and/or ability to interact with display  104  and/or electronic device  100 . Transparent layer  108  may be formed from a variety of substantially transparent materials including, but not limited to: sapphire, glass or plastic. 
     Button  106  may include any conventional input/output (I/O) device for electronic device  100 . Specifically, button  106  may include an actuation component (see,  FIG. 4 ) in electronic and/or mechanical communication with the internal components of electronic device  100 , to provide user input and/or allow the user to interact with the various functions of electronic device  100 . In an embodiment button  106  may be configured as a single component surrounded by enclosure  102 . Alternatively, button  106  may include a plurality of components, including an actuation component, in mechanical/electrical communication with one another and/or internal component of electronic device  100 . Button  106  may be formed from a transparent material, similar to transparent layer  108 . That is, at least a portion of button  106  may be formed from a substantially transparent material including, but not limited to: sapphire, glass or plastic. 
     As shown in  FIGS. 1A and 1B , electronic device  100  may also include a plurality of camera systems. More specifically, electronic device  100  may include a first camera system  110  positioned on the front surface  112  of electronic device  100  (see,  FIG. 1A ) and a second camera system  118  positioned on the back surface  120  of electronic device  100  (see,  FIG. 1B ). Similar to display  104  of electronic device  100 , first camera system  110  and second camera system  118  may include a transparent layer positioned within enclosure  102 . In an non-limiting example as shown in  FIG. 1B , second camera system  118  may include a window  122  that may be positioned in front of the internal components of second camera system  118  and may be positioned within enclosure  102 . As discussed herein, window  122  of second camera system  118  may be positioned within an aperture of enclosure  102 , such that enclosure  102  and window  122  are in planar alignment with back surface  120  of electronic device  100 . Also similar to transparent layer  108  of display  104 , window  122  may be formed from a plurality of substantially transparent materials including, but not limited to: sapphire, glass, or plastic. Window  122  may be configured to provide a transparent protective layer for second camera system  118  that may protect second camera system  118  from contaminants, without obstructing electronic device&#39;s  100  ability to take images and/or videos using second camera system  118 . 
       FIG. 2A  shows an exploded, simplified cross-section view of a portion of electronic device  100  along line  2 - 2  in  FIG. 1B . More specifically,  FIG. 2A  shows an exploded, simplified cross-section view of enclosure  102  and second camera system  118  including window  122  of electronic device  100 . Enclosure  102  of electronic device  100  may include a plurality of distinct apertures formed therein or therethrough. Each of the plurality of apertures may be configured to receive a distinct component (e.g., window  122 , transparent layer  108  of display  104 , button  106 ) of electronic device  100 . 
     As shown in  FIG. 2A , and as discussed herein, aperture  124  formed through enclosure  102  may be configured to receive window  122  of second camera system  118 . Aperture  124  may be formed through the body of enclosure  102  and may form a passageway between an exposed or exterior surface (e.g., back surface  120 ) and an interior surface  126  of enclosure  102 . As shown in  FIG. 2A , the exterior surface may include back surface  120  of electronic device  100 , and interior surface  126  may include a surface positioned within enclosure  102  and/or between back surface  120  and front surface  112  (see,  FIG. 1A ) of electronic device  100 . Interior surface  126  may be positioned adjacent an internal cavity  128  of electronic device  100 , which may house the internal components of electronic device  100 . 
     The plurality of apertures (e.g., aperture  124 ) of enclosure  102  may be configured to receive a component or components (such as, window  122 , transparent layer  108  of display  104 , button  106 ) of electronic device  100  by having a complementary shape of the component, which includes any shape configured to accept and/or retain such a component. As discussed herein, by including complementary shapes, the component of electronic device  100  positioned within the aperture of enclosure  102  may also be adequately coupled (e.g., welded) to enclosure  102  of electronic device  100 . 
     In an non-limiting example, as shown in  FIGS. 2A and 2B , aperture  124  of enclosure  102  may include angled sidewalls  130  that may be complementary to the sidewalls  132  of window  122 . More specifically, sidewalls  130  of aperture  124  in enclosure  102  may include an angle substantially equal to the angle of sidewalls  132  of window  122  of second camera system  118 . By having sidewalls that complement the angle and shape of the sidewalls of the window  122  may be positioned within aperture  124  of enclosure  102 , and sidewalls  130  of aperture  124  and sidewalls  132  of window  122  may substantially contact one another. 
     Second camera system  118  may include internal camera components  134  positioned adjacent window  122 . Internal camera components  134  may be positioned within internal cavity  128  of electronic device  100 , adjacent interior surface  126  of enclosure  102 . As shown in  FIG. 2A , internal camera components  134  may include any conventional component(s) used in second camera system  118 , including a lens, a magnifier, a shutter, diaphragm, etc. Additional explanation of these components is omitted herein for clarity. 
     Window  122  of second camera system  118  may include a first surface  136  and a second surface  138  positioned opposite first surface  136 . As discussed herein, when window  122  is positioned within enclosure  102 , first surface  136  may be an external surface and may be substantially exposed to the exterior of electronic device  100  and/or may be in planar alignment with the exterior surface or back surface  120  of electronic device  100 . Furthermore, and as discussed herein, when window  122  is positioned within enclosure  102 , second surface  138  may include an internal surface positioned adjacent interior surface  126  of enclosure  102  and/or may be positioned within cavity  128  of electronic device  100 . 
     First surface  136  and second surface  138  of window  122  may include surface treatments. More specifically, prior to, or subsequent to, positioning window  122  within enclosure  102 , first surface  136  and second surface  138  may undergo surface treatment processes including, but not limited to: lapping, planing, grinding, or polishing. In a non-limiting example, first surface  136  and second surface  138  may be polished prior to positioning window  122  within enclosure  102  to substantially ensure that window  122  includes an acceptable transparency that will not obstruct second camera system  118 . The surface treatment processes may be performed on window  122  prior to and/or subsequent to the forming (e.g., cutting, shaping) of window  122 . 
     As shown in  FIG. 2A , sidewalls  132  of window  122  may be positioned between treated first surface  136  and treated second surface  138 , and may be substantially angled, as discussed herein. Unlike treated first surface  136  and treated second surface  138 , sidewalls  132  of window  122  may not be treated. That is, sidewalls  132  of window  122  may not undergo surface treatment processes prior to window  122  being positioned within aperture  124  of enclosure  102 . 
     As a result of not performing surface treatment processes on sidewalls  132 , untreated sidewalls  132  of window  122  may include defects  140 .  FIG. 2B , shows an enlarged portion of sidewalls  132  of window  122  as depicted in  FIG. 2A . As shown in  FIG. 2B , defects  140  may be formed on the surface of sidewalls  132  of window  122  as a result of the forming processes (e.g., cutting, shaping) utilized when forming window  122 . In a non-limiting example, window  122  may be formed from a transparent, sapphire material. More specifically, window  122  may be formed by cutting window  122  from a large sheet of sapphire material. Because sapphire is hard and brittle, the cutting process used to form window  122  may create defects  140  on one or more of the various surfaces (e.g., sidewalls  132 , first surface  136 , second surface  138 ) of the sapphire. Surface treatment processes performed on first surface  136  and second surface  138  may remove these defects  140  formed on the respective surfaces. However, untreated sidewalls  132  of window  122  may maintain defects  140  when positioned within aperture  124  of enclosure  102 . As shown in  FIG. 2B , defects  140  of sidewalls  132  may include a plurality of cracks  142  and/or depressions  144 . As discussed herein, defects  140  may not negatively affect the coupling between window  122  and enclosure  102 . 
       FIG. 2C  shows a cross-section view of window  122  of second camera system  118  positioned within aperture  124  of enclosure  102 . As discussed herein, aperture  124  of enclosure  102  may include a complementary shape (e.g., angled sidewalls  130 ) for receiving window  122 . Window  122  may be positioned within aperture  124  such that treated first surface  136  or external surface of window  122  may be in planar alignment with exterior surface or back surface  120  of enclosure  102 . That is, as shown in  FIG. 2C , the exposed surfaces (e.g., treated first surface  136 , back surface  120 ) of window  122  and enclosure  102  may be in planar alignment, such that treated first surface  136  of window  122  and back surface  120  of enclosure  102  form a continuous, smooth surface. 
     Window  122  may also be coupled to enclosure  102 . More specifically, as shown in  FIG. 2C , window  122  may be welded to enclosure  102  and may be substantially fixed within aperture  124  of enclosure  102 . As discussed herein, and as shown in  FIG. 2C , enclosure  102  may include a protective casing for electronic device  100 , where window  122  is welded to enclosure  102  forming the protective casing. In another non-limiting example, and as discussed herein, where enclosure  102  includes a plurality of components, and specifically where enclosure  102  includes a trim piece, window  122  may be welded to the trim piece forming enclosure  102 . 
     In coupling window  122  to enclosure  102 , a weld interface  146  may be present between sidewalls  130  of enclosure  102  and untreated sidewalls  132  of window  122  to couple the components of electronic device  100 . As shown in  FIG. 2C , weld interface  146  may be positioned between treated first surface  136  or external surface of window  122 , and treated second surface  138  or internal surface of window  122 . Additionally, weld interface  146  may be positioned between exterior surface or back surface  120  and interior surface  126  of enclosure  102 . As shown in  FIG. 2C , weld interface  146  may be formed around an entire perimeter of sidewalls  130  of aperture  124  and/or untreated sidewalls  132  of window  122  to ensure window  122  is substantially coupled or fixed to enclosure  102 . Weld interface  146  may include a solidified molten pool or deposit of material forming enclosure  102 , that may couple or weld enclosure  102  to window  122 . As discussed herein, a portion of sidewall  130  of enclosure  102  may be exposed to a laser beam, which may create molten pool of a portion of material forming sidewalls  130  to weld enclosure  102  to window  122 . 
       FIG. 2D  shows an enlarged portion of weld interface  146  as depicted in  FIG. 2C . As discussed herein, weld interface  146  may be formed between sidewalls  130  of enclosure  102  and untreated sidewalls  132  of window  122  from a solidified molten pool of material forming enclosure  102 . As a result of the weld being formed from the solidified molten pool of material forming enclosure  102 , weld interface  146  may also be formed within defects  140  of untreated sidewalls  132  of window  122 . More specifically, as shown in  FIG. 2D , weld interface  146  may be formed within cracks  142  and/or depressions  144  previously formed within untreated sidewalls  132  of window  122  when forming (e.g., cutting) window  122 . By forming weld interface  146  within defects  140  of untreated sidewall  132  of window  122 , weld interface  146  may completely contact the entire surface of sidewall  130  to fix window  122  to enclosure  102 . Additionally, potential issues with defects  140  may be substantially minimized when forming weld interface  146  within defects  140  of untreated sidewall  132  of window  122 . In a non-limiting example, depression  144  formed in untreated sidewalls  132  of window  122  may substantially increases the chance of window  122  being split during an undesirable impact event (e.g., dropping electronic device  100 ). However, weld interface  146  may fill depression  144  formed in untreated sidewalls  132  of window  122 , and may provide additional structure support to window  122  and/or may provide a binding-effect within depression  144  to prevent further defect within window  122 . 
     As a result of angled sidewalls  132  of window  122  and corresponding angled sidewalls  130  of enclosure  102 , weld interface  146  may not be visible to a user of electronic device  100 . More specifically, because the respective angled sidewalls for window  122  and enclosure  102  extend toward internal cavity  128  and/or enclosure  102 , a user of electronic device  100  viewing back surface  120  may not be able to see weld interface  146 . As such, a “hidden weld” may be formed to couple window  122  to enclosure  102  of electronic device  100 . 
       FIG. 3  shows a front cross-section view of a portion of electronic device  100  along line  3 - 3  in  FIG. 1A . More specifically,  FIG. 3  shows a front cross-section view of transparent layer  108  of display  104  positioned within enclosure  102  in electronic device  100 . It is understood that similarly named and/or numbered components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
     Transparent layer  108  of electronic device  100  may include first surface  336 , which may be exposed to a user. More specifically, as shown in  FIG. 3 , transparent layer  108  may be positioned within enclosure  102 , such that first surface  336  of transparent layer  108  may be an external surface, and may be substantially exposed to the exterior of electronic device  100  and/or may be in planar alignment with the exterior surface or front surface  112  of electronic device  100 . Additionally, when transparent layer  108  is positioned within aperture  324  of enclosure  102 , the exposed surfaces (e.g., treated first surface  336 , front surface  112 ) of transparent layer  108  and enclosure  102  may be in planar alignment, such that treated first surface  336  of transparent layer  108  and front surface  112  of enclosure  102  form a continuous, smooth surface. 
     As shown in  FIG. 3 , display  104 , which may include a touchscreen, may be positioned on or adjacent to second surface  338  or internal surface of transparent layer  108  of electronic device  100 . Additionally, display  104  may be positioned within internal cavity  128  and/or adjacent to interior surface  126  of enclosure  102 . As discussed herein transparent layer  108  may be configured as a protective layer for display  104 . 
     As similarly discussed herein with respect to window  122 , first surface  336  and second surface  338  of transparent layer  108  may include a surface treatment. That is, first surface  226  and second surface  338  of transparent layer  108  may undergo surface treatment(s) prior to transparent layer  108  being positioned within aperture  324  of enclosure  102 . To the contrary of treated first surface  336  and treated second surface  338 , but similar to sidewalls  132  of window  122  in  FIGS. 2A-2D , sidewalls  332  of transparent layer  108  may include untreated sidewalls  332 . As a result, untreated sidewalls  332  of transparent layer  108  may include defects  140  as a result of forming (e.g., cutting) transparent layer  108  of electronic device  100 . 
     Similar to window  122  shown in  FIGS. 2A-2D , transparent layer  108  of electronic device  100 , as shown in  FIG. 3 , may also be coupled or welded to enclosure  102 . More specifically, transparent layer  108  may be fixed within aperture  324  of enclosure  102  via weld interface  146  present between sidewalls  130  of enclosure  102  and untreated sidewalls  332  of transparent layer  108 . As shown in  FIG. 3 , and similarly discussed herein, weld interface  146  may be positioned between external or treated first surface  336  and internal or treated second surface  138  of transparent layer  108  and, exterior or front surface  112  and interior surface  126  of enclosure  102 . Additionally, weld interface  146  may be formed around an entire perimeter of sidewalls  130  of aperture  324  and/or untreated sidewalls  332  of transparent layer  108  to ensure transparent layer  108  is substantially coupled or welded to enclosure  102 . As discussed herein, weld interface  146  may include a solidified molten pool of material forming enclosure  102 , that may couple or weld transparent layer  108  to enclosure  102 . 
     As shown in  FIG. 3 , an adhesive  348  may be positioned in aperture  324  formed through enclosure  102  and transparent layer  108 . That is, adhesive  348  may be positioned between sidewalls  130  of enclosure  102  and untreated sidewalls  332  of transparent layer  108 , and may be positioned adjacent weld interface  146 . Adhesive  348 , as shown in  FIG. 3  may also be positioned between positioned between external or treated first surface  336  and internal or treated second surface  138  of transparent layer  108 , and exterior or front surface  112  and interior surface  126  of enclosure  102 . In a non-limiting example, adhesive  348  may be positioned between weld interface  146  and external or treated first surface  336  of transparent layer  108  and/or exterior or front surface  112  of enclosure  102 . Adhesive  348  may be formed between weld interface  146  and the external surfaces of transparent layer  108  and/or enclosure  102  for functional and/or cosmetic purposes. In a non-limiting example of functionality, adhesive  348  may be formed between enclosure  102  and transparent layer  108  to adhere and/or aid in the coupling of transparent layer  108  to enclosure  102 . In a non-limiting example of cosmetic application, adhesive  348  may be formed between enclosure  102  and transparent layer  108  to hide weld interface  146 . That is, adhesive  348  may be provided in electronic device  100  (see,  FIG. 1A ) to substantially prevent a user of electronic device  100  from seeing weld interface  146  formed between enclosure  102  and transparent layer  108 , where weld interface  146  may not be “hidden” from a user due to the configuration or shape of the components (e.g., enclosure  102 , transparent layer  108 ) of electronic device  100 . Adhesive  348  formed in aperture  324  of enclosure  102  may be any conventional adhesive material capable of adhering transparent layer  108  to enclosure  102 . 
     Although shown and discussed herein as being used with transparent layer  108 , it is understood that adhesive  348  of  FIG. 3  may be utilized with any component of electronic device  100  positioned in, and welded to, enclosure  102 . That is, adhesive  348  may be utilized with window  122 , as discussed herein with respect to  FIGS. 2A-2D , and button  106 , as discussed herein with respect to  FIG. 4 . 
       FIG. 4  shows a front cross-section view of a portion of electronic device  100  along line  4 - 4  in  FIG. 1A . More specifically,  FIG. 4  shows a front cross-section view of button  106  positioned within enclosure  102  in electronic device  100 . Button  106  may include a button housing  452  made from a substantially transparent material (e.g., sapphire, glass, plastic), and an actuation component  450  positioned within button housing  452  of button  106 . Actuation component  450  may be configure to move within button housing  452  in a direction (D), while button housing  452  remains substantially stationary and/or welded to enclosure  102 , as discussed herein. Additionally, actuation component  450  of button  106  may be in mechanical and/or electronic communication with an internal button component  454  of electronic device  100 . In a non-limiting example, internal button component  454  may include a piezoelectric sensor that may be in electro-mechanical communication with actuation component  450 . When actuation component  450  of button  106  is actuated by a user, actuation component  450  contacts and/or deforms the piezoelectric sensor to send an electronic signal to distinct, internal components of electronic device  100 . 
     As shown in  FIG. 4 , enclosure  102  may include a bezel portion  456 . More specifically, sidewalls  130  of enclosure  102  may include bezel portion  456 , which may complement a protrusion portion  458  of button housing  452  of button  106 . When button  106  includes protrusion portion  458 , and enclosure  102  includes complementary bezel portion  456 , weld interface  146  may be formed on and/or between protrusion portion  458  and bezel portion  456  to weld button  106  to enclosure  102 . More specifically, as shown in  FIG. 4 , weld interface  146  may be formed between a portion of sidewalls  130  of bezel portion  456  of enclosure  102  and a portion of untreated sidewalls  432  of protrusion portion  458  of button  106  to weld button housing  452  of button  106  to enclosure  102 . Weld interface  146  may be positioned between external or treated first surface  436  and internal or treated second surface  438  of button  106  and, exterior or front surface  112  and interior surface  126  of enclosure  102 . Additionally, weld interface  146  may be formed around an entire perimeter of bezel portion  456  of enclosure  102  and/or protrusion portion  458  of button housing  452  to ensure button  106  is substantially coupled or welded to enclosure  102 . 
     By providing weld interface  146  between protrusion portion  458  of button housing  452  and bezel portion  456  of enclosure  102 , weld interface  146  may not be visible, or may be “hidden” from a user viewing front surface  112  of electronic device  100 . More specifically, bezel portion  456  of enclosure  102  may be positioned on top of and/or may extend over protrusion portion  458  of button housing  452 , such that protrusion portion  458  is not visible from front surface  112  of electronic device  100 . As a result, weld interface  146  may also be covered and/or not visible from front surface  112  because of bezel portion  456 . 
     Turning to  FIG. 5 , a method of securing a component within an electronic device enclosure (see,  FIGS. 1A and 1B ) is now discussed. Specifically,  FIG. 5  is a flowchart depicting one sample method  500  for securing a component within an electronic device enclosure, as discussed herein with respect to  FIGS. 1A-4 . 
     In operation  502 , an electronic device enclosure including at least one aperture is provided. More specifically, at least one aperture may be formed through an enclosure of an electronic device for allow components of the electronic device to be viewable by a user and/or protected from contaminants. 
     In optional operation  504 , an adhesive may be applied to at least one of the at least one aperture formed through the electronic device enclosure, and/or a component configured to be positioned within the aperture. That is, an adhesive may be applied to a portion of the sidewalls of the apertures formed through the electronic device enclosure. Additionally, an adhesive may be applied to a portion of the component that may contact the sidewalls of the apertures when the component is positioned within the aperture. As discussed herein, the adhesive may be applied to the aperture and/or the component to adhere the component to the enclosure and/or hide a weld formed between the electronic device enclosure and the component. 
     In operation  506 , the component may be positioned within the aperture formed through the electronic device enclosure. More specifically, a component of the electronic device, formed from a transparent material, may be positioned within and/or received by the aperture of the electronic device enclosure. As discussed herein, the aperture of the enclosure may include a complementary shape to the shape of the component. That is, the sidewalls of the aperture of the enclosure may be complementary to the sidewalls of the component positioned within the enclosure. In non-limiting examples, and as discussed herein, the component positioned within the aperture of the enclosure may include a window for a camera system (see,  FIGS. 2A-2D ), a transparent layer for a display (see,  FIG. 3 ), or a button (see,  FIG. 4 ). 
     The component positioned within the aperture of the electronic device enclosure may include additional processes prior to, or subsequent to, the positioning in operation  506 . More specifically, the an external surface of the component may be treated, and the internal surface of the component positioned opposite the external surface may be treated. The external surface and internal surface may undergo surface treatments, such as, lapping, planing, grinding, or polishing. Additionally, prior to, subsequent to, and/or during the positioning in operation  506 , untreated sidewalls of the component may be substantially maintained. More specifically, the sidewalls of the component may remain substantially untreated, or may not undergo surface treatments, such that the sidewalls contain defects (e.g., cracks, depressions) formed during initially processes for creating the component. 
     The positioning in operation  506  may also include aligning the treated external surface of the component with an exterior surface of the electronic device enclosure. More specifically, when positioning the component within the aperture, the treated external surface of the component may be in planar alignment with an exterior surface of the enclosure. By aligning the external surface of the component and the exterior surface of the enclosure, the surface of the electronic device including the component and/or the aperture may be substantially continuous and planar. 
     In operation  508 , the component may be welded to the electronic device enclosure. More specifically, a laser beam may be projected through the component including the transparent material, and a portion of the sidewall of the aperture formed through the enclosure may be exposed to the projected laser beam. The laser beam wavelength may be dependent on the material composition of the component, such that material of the component is transparent to the laser beam. As a result of the laser beam being projected through the component, the material of the component may also include a melting point greater than the melting point of the material forming the enclosure. When the laser beam is exposed to a portion of the sidewall of the enclosure through the component, the exposed portion of the sidewall may include a solidified molten pool that may weld the sidewall of the component to the sidewall of the aperture of the enclosure. The welding may also include laser welding an entire perimeter of the component to the at least one aperture formed through the enclosure. By welding the perimeter of the component, it may substantially ensure that the component is fixed to the enclosure. 
     Turning to  FIGS. 6A-6D , a sample portion of an electronic device  100  (see,  FIGS. 1A and 1B ) including an enclosure  102  and a window  122 , is shown undergoing various operations of method  500  of  FIG. 5 . It is understood that similarly numbered components may function in a substantially similar fashion. Redundant explanation of these components has been omitted for clarity. 
     As shown in  FIG. 6A , enclosure  102  of electronic device  100  (see,  FIGS. 1A and 1B ) may be provided and may include an aperture  124 , as discussed herein. The provided enclosure  102  including the aperture  124 , as shown in  FIG. 6A , may correspond to operation  502  of  FIG. 5 . Aperture  124  of enclosure  102  may include angled sidewalls  130 , which may complement or correspond to untreated sidewalls  132  of window  122 , as discussed herein. 
     Also shown in  FIG. 6A , window  122  may be positioned within aperture  124  of enclosure  102 , as discussed herein. More specifically, untreated sidewalls  132  of window  122  may contact sidewalls  130  of enclosure  102 , and treated external or first surface  136  may be in planar alignment with exterior or back surface  120  of enclosure  102 . Window  122  positioned within aperture  124  of enclosure  102 , as shown in  FIG. 6A , may correspond to operation  506  of  FIG. 5 . 
     Although not shown in  FIG. 6A , it is understood that an adhesive may also be applied to the aperture formed through enclosure  102  prior to the positioning of window  122  within aperture  124  of enclosure  102 . More specifically, an adhesive  348  (see,  FIG. 4 ) may be applied to sidewall  130  of aperture  124  to aid in adhering window  122  to enclosure  102  and/or hid a weld formed between enclosure  102  and window  122 , as discussed herein. The applying of an adhesive to the aperture, if shown in  FIG. 6A , would correspond to operation  504  in  FIG. 5 . 
     Turning to  FIGS. 6B-6D , window  122  may be welded to enclosure  102 , as discussed herein. Specifically,  FIGS. 6B-6D  show the progression of the laser welding process for welding window  122  to aperture  124  of enclosure  102 . Window  122  welded to enclosure  102 , as shown in  FIGS. 6B-6D , may correspond to operation  508  in  FIG. 5 . As shown in FIG.  6 B, the welding process may begin on a first side of aperture  124 . Laser  660  may project a laser beam  662  through window  122 , which includes a transparent material, to expose a portion of sidewall  130  of aperture  124  formed through enclosure  102 . As discussed herein, laser  660  may include a predetermined wavelength that may be dependent on the transparency properties of the material forming window  122 , such that window  122  is substantially transparent to laser beam  662  of laser  660 . Additionally, and as discussed herein, the material forming window  122  may include a melting point higher than the material forming enclosure  102 . As a result, window  122  may be substantially unaffected when laser beam  662  is projected through window  122  and a portion of sidewall  130  of enclosure  102  is exposed to laser beam  662 , during the welding process. 
     In a non-limiting example, where window  122  is formed from sapphire and enclosure  102  is formed from aluminum, laser  660  may include an infrared laser, which may produce laser beam  662  having a 1064 nm wavelength, and 150 W average power. Laser  660  may be a pulsed laser capable of pulsing laser beam  662  in micro-second pulse widths. Because sapphire&#39;s melting point (e.g., approximately 2000° C.) is greater than aluminum&#39;s melting point (e.g., approximately, 1220° C.), laser beam  662  pulsing through window  122  may form a molten pool of the aluminum on sidewall  130 , which may ultimately create weld interface  146  (see,  FIG. 6C ), without disrupting the sapphire forming window  122 . In an additional non-limiting example, laser  660  may be a continuous wave laser. Distinct from the pulsed laser, continuous wave laser may provide a continuous laser beam  662  through window  122 , which includes a transparent material, to expose a portion of sidewall  130  of aperture  124  formed through enclosure  102 , as discussed herein. 
     Window  122  may be substantially circular in shape (see,  FIG. 1B ). As such, and as shown in  FIGS. 6B and 6C , laser  660  may rotate in direction (R) to perform a circumferential weld of window  122  and enclosure  102 . The circumferential weld performed by laser  660  may provide a complete perimeter weld of window  122  to ensure window  122  is fixed to enclosure  102 , as discussed herein. During the circumferential welding process, as depicted in  FIGS. 6B and 6C , the exposed portion of sidewall  130  of enclosure  102  may form a molten pool that may subsequently solidify, to form weld interface  146 . Specifically, when comparing  FIGS. 6B and 6C , the portion of sidewall  130  that is exposed to laser beam  662  in  FIG. 6B  may be solidified to form weld interface  146  by the time laser beam  662  is projected on a portion of sidewall  130  positioned opposite weld interface  146 , as shown in  FIG. 6C . 
     As shown in  FIG. 6D , window  122  may be completely welded to enclosure  102 . More specifically, laser  660  may weld the entire perimeter of window  122  and may be positioned back in alignment with the portion of sidewall  130  initially exposed to laser beam  662 , as shown in  FIG. 6B . As result of welding the entire perimeter of window  122 , laser  660  may no longer expose sidewalls  130  of aperture  124  formed through enclosure  102  with laser beam  662 . Additionally, as shown in  FIG. 6D , weld interface  146  may be formed completely around window  122 , for welding and/or fixing window  122  to enclosure  122 . 
     Although the material forming window  122  is discussed herein as having a melting point higher than the material forming the enclosure  102 , it is understood that window  122  may also include a melting point equal to or less than the melting point of the material forming the enclosure  102 . That is, in non-limiting examples, the material forming window  122  may include a melting point equal to, or less than the material forming enclosure  102 . In these examples, window  122  may remain substantially unaffected when laser beam  662  is projected through window  122 , as discussed herein, or may be minimally altered by laser beam  662 . In these non-limiting examples, when window  122  is exposed to laser beam  662 , window  122  may be substantially unaffected by laser beam  662 , as discussed herein, or laser beam  662  may cause a minimal, surface alteration to window  122 . Although the material forming window  122  may include a melting point equal to, or less than the material forming enclosure  102 , window  122  may remain substantially unaffected or minimally affected as a result of laser beam  662  including a wavelength that provides window  122  to be substantially transparent to laser beam  662  of laser  660 . Where window  122  includes a minimal surface alteration as a result of laser beam  662 , the minimal surface alteration may remain on second surface  138  of window  122  undetectable and/or unseen by a user or, may be removed by performing additional surface treatment processes (e.g., buffing, polishing) on second surface  138  of window  122 . 
     By welding the components (e.g., window, button) of the electronic device to the enclosure of the electronic device, the need for an adhesive to bind the components is unnecessary. Also, in welding the components of the electronic device to the enclosure, the need for decorative ink to hide the coupling technique (e.g., the weld) may be unnecessary, as the weld is substantially small and/or undetectable by a user of the electronic device. Additionally, by welding the components to the enclosure of the electronic device, a substantially permanent coupling may be formed between the components and the enclosure. Furthermore, by forming the laser weld between the components and the enclosure by emitting a laser beam through the transparent material forming the components, the weld may be substantially hidden from the user of the electronic device. That is, by laser welding the respective components, the weld may be substantial undetectable by, or concealed from, the user of the electronic device. Not only will the laser weld improve the coupling strength between the first and second component, but it may also improve the cosmetic features of the electronic device. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20140331
Publication Date: 20171010
Grant Date: 20171010
Priority Date: 20140331
Inventors: AMES LOGAN M.
LI MICHAEL M.
Assignee: APPLE INC
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Family ID: 53274785