PATENT DOCUMENT

Publication Number: US-9910460-B2
Application Number: US-201514815376-A
Country: US
Kind Code: B2

Title: Micro-perforation overmolding gate

Abstract:
An electronic device having protruding features and a method for molding the protruding features to the electronic device are described. The protruding features may be formed by a molding tool that releases a material that flows through several apertures of a substrate. Also, the molding tool is positioned with respect to the substrate such that the material from the molding tool flows from an interior region of the substrate to an exterior region of the substrate via the several apertures. Accordingly, each aperture extends from an opening of the interior region and to an opening of the exterior region of the substrate. In some cases, the apertures may include a conical shape. For example, the opening in the interior region may include a diameter greater than a diameter of the opening in the exterior region. In this manner, the material, when cured, is mechanically secured to the substrate.

Claims:
What is claimed is: 
     
       1. A molding tool configured to mold a feature to a substrate having an interior region and an exterior region opposite the interior region, the molding tool comprising:
 a first chamber configured to align with and fill first micro-apertures formed through the substrate with a moldable material used to form the feature; 
 a second chamber configured to align with second micro-apertures formed through the substrate; and 
 a mold cavity that communicates with the first chamber and the second chamber via the first micro-apertures and the second micro-apertures, respectively, the mold cavity comprising an internal cavity having a shape of the feature. 
 
     
     
       2. The molding tool of  claim 1 , wherein at least one of the first micro-apertures comprises a first opening having a first cross sectional area at the interior region, and a channel through the substrate that connects the first opening with a second opening having a second cross sectional area at the exterior region. 
     
     
       3. The molding tool of  claim 2 , wherein the first cross sectional area is about equal to the second cross sectional area. 
     
     
       4. The molding tool of  claim 2 , wherein at least some of the moldable material remains within at least one of the channels. 
     
     
       5. The molding tool of  claim 1 , wherein the moldable material is a low viscosity liquid polymer. 
     
     
       6. The molding tool of  claim 5 , wherein the low viscosity liquid polymer is selected from a group comprising liquid silicone rubber, urethane acrylate, and a two-part resin. 
     
     
       7. An electronic device, comprising:
 a substrate comprising an interior region and an exterior region, the exterior region defining a visible region of the substrate when the electronic device is assembled; 
 a plurality of micro-apertures, comprising:
 a first micro-aperture extending from a first opening in the interior region to a second opening in the exterior region, the first opening having a first diameter, the second opening having a second diameter; and 
 a second micro-aperture extending from a third opening in the interior region to a fourth opening in the exterior region; and 
 
 a polymer feature extending from the exterior region to the interior region, wherein a portion of the polymer feature is positioned within the first micro-aperture and the second micro-aperture. 
 
     
     
       8. The electronic device of  claim 7 , wherein the polymer feature is formed of a low viscosity liquid polymer selected from a group comprising liquid silicone rubber, urethane acrylate, and a two-part resin or other low viscosity molding polymer. 
     
     
       9. The electronic device of  claim 8 , wherein the low viscosity liquid polymer is translucent or transparent or opaque. 
     
     
       10. The electronic device of  claim 9 , further comprising a light source, wherein when the light source is activated the low viscosity polymer allows the light to pass through the low viscosity polymer to illuminate the polymer feature. 
     
     
       11. The electronic device of  claim 7 , wherein the polymer feature comprises:
 a mechanical interlock in the interior region; 
 a cosmetic exterior that hides the first micro-aperture, the second micro-aperture, and the mechanical interlock. 
 
     
     
       12. The electronic device of  claim 7 , wherein the polymer feature protrudes relative to the exterior region of the substrate to define an exterior surface of the polymer feature. 
     
     
       13. The electronic device of  claim 12 , wherein the exterior surface of the polymer feature is rounded. 
     
     
       14. The electronic device of  claim 12 , wherein the exterior surface of the polymer feature defines a polygonal shape. 
     
     
       15. The electronic device of  claim 12 , wherein the exterior surface of the polymer feature comprises a flat region. 
     
     
       16. The electronic device of  claim 7 , wherein the plurality of micro-apertures comprises a first region of micro-apertures surrounded by a second region of micro-apertures. 
     
     
       17. The electronic device of  claim 16 , wherein the polymer feature covers the first region of micro-apertures and the second region of micro-apertures. 
     
     
       18. The electronic device of  claim 7 , wherein the second diameter is less than the first diameter. 
     
     
       19. The electronic device of  claim 7 , wherein the first micro-aperture defines a conical shape. 
     
     
       20. The electronic device of  claim 7 , wherein the first micro-aperture defines a cylindrical shape.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 62/078,893, entitled “MICRO-PERF OVERMOLDING GATE” filed Nov. 12, 2014, the content of which is incorporated herein by reference in its entirety for all purposes. 
    
    
     FIELD 
     The described embodiments relate generally to features of an electronic device. In particular, the present embodiments relate to protruding features formed from a liquid polymer and secured with a portable electronic device. 
     BACKGROUND 
     Portable electronic devices known in the art may include one or more protruding features, or “feet,” which extend from a base portion an electronic device. These feet can be secured to the base portion such that the feet engage a surface (for example, a desk or table) on which the electronic device lies. Multiple techniques are known for securing the protruding features to the electronic device. For instance, each protruding feature may be adhesively secured to the electronic device. Alternatively, each foot may be molded onto the bottom portion by simply curing a fluid onto an exterior surface of the base portion. 
     However, these techniques have drawbacks. One or more protruding feature(s) may become delaminated in either the adhesive technique or the molding technique previously described, and detach from the based portion. Further, when the protruding features are adhesively secured and become delaminated, the feet may tend to secure to other objects nearby which is undesired. In either case, the protruding features are prone to falling off of the electronic device. 
     SUMMARY 
     In one aspect, a method for forming a polymer feature to a substrate having an interior region and an exterior region opposite the interior region is described. The method may include sending a material in a fluid form through a first micro-aperture using a molding tool. The first micro-aperture may be formed in the substrate and include a first opening having a first cross sectional area at the interior region. Also, a channel may be formed through the substrate that connects the first opening with a second opening having a second cross sectional area at the exterior region. The method may further include receiving the material from the channel at the exterior region via the second opening. In some embodiments, some of the material remains within the channel. Also, the method may further include allowing gas from within the material to escape at a second micro-aperture. 
     In another aspect, a molding tool configured to mold a feature to a substrate having an interior region and an exterior region opposite the interior region is described. The molding tool may include a first chamber configured to align with and fill first micro-apertures formed through the substrate with a moldable material used to form the feature. The molding tool may further include a second chamber configured to align with second micro-apertures formed through the substrate. The molding tool may further include a mold cavity that communicates with the first chamber and the second chamber via the first micro-apertures and the second micro-apertures, respectively. The mold cavity may include an internal cavity having a shape of the feature. In some embodiments, the feature is formed to the substrate by moving the moldable material from the first chamber through at least one of the first micro-apertures to the internal cavity of the mold cavity. The feature is further formed by removing gas from the mold cavity through at least one of the second micro-apertures. The feature is further formed by continuing the moving of the moldable material and removing the gas mold cavity until the internal cavity is substantially filled or until the shape of the feature is completed. 
     In another aspect, an electronic device is described. The electronic device may include a substrate that includes an interior region and an exterior region. The exterior region may define a visible region of the substrate when the electronic device is assembled. The electronic device may further include several micro-apertures. The several micro-apertures may include a first micro-aperture extending from a first opening in the interior region to a second opening in the exterior region. The first opening may include a first diameter, and the second opening may include a second diameter. The several micro-apertures may further include a second micro-aperture extending from a third opening in the interior region to a fourth opening in the exterior region. The third opening may include a third diameter. The electronic device may further include a polymer feature extending from the exterior region to the interior region. In some embodiment, a portion of the polymer feature is positioned within the first micro-aperture and the second micro-aperture. 
     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 an electronic device; 
         FIG. 2  illustrates an isometric view of an alternative embodiment of an electronic device; 
         FIG. 3  illustrates an isometric view of a substrate that may be part of a base, or lower region, of an electronic device, in accordance with the described embodiments; 
         FIG. 4  illustrates a side view of the substrate shown in  FIG. 3 , showing a first dimension of the substrate; 
         FIG. 5  illustrates an alternate side view of the substrate shown in  FIG. 3 , showing a second dimension of the substrate; 
         FIG. 6  illustrates a plan view of an interior region of a substrate that includes multiple regions of apertures extending through the substrate, in accordance with the described embodiments; 
         FIG. 7  illustrates a plan view of the substrate shown in  FIG. 6 , oriented to show an exterior region of the substrate; 
         FIG. 8  illustrates an enlarged plan view showing a portion of an interior region of a substrate having an alternate pattern of several apertures extending through the substrate, in accordance with the described embodiments; 
         FIG. 9  illustrates an enlarged plan view of the substrate shown in  FIG. 8 , oriented to show the exterior region of the substrate; 
         FIG. 10  illustrates a cross sectional view of the substrate shown in  FIG. 8 , taken along the  10 - 10  line; 
         FIG. 11  illustrates a cross sectional view of an alternate embodiment of a portion of a substrate, in accordance with the described embodiments; 
         FIG. 12  illustrates a partial cross sectional view of the substrate shown in  FIG. 10 , with a cross section of a molding tool configured to mold a protruding feature to the substrate, in accordance with the described embodiments; 
         FIG. 13  illustrates the partial cross sectional view of the substrate and the molding tool shown in  FIG. 12 , showing the molding tool filling the substrate with a material used to form the protruding feature; 
         FIG. 14  illustrates the partial cross sectional view of the substrate and the molding tool shown in  FIG. 13 , showing the molding tool having filled a mold cavity of the molding tool with the material used to form the protruding feature; 
         FIG. 15  illustrates the partial cross sectional view of the substrate and the molding tool shown in  FIG. 14 , showing the molding tool using a vacuum to remove gas molecules from the material used to form the protruding feature; 
         FIG. 16  illustrates a cross sectional view of a protruding feature formed using the molding tool previously described, in accordance with the described embodiments; 
         FIG. 17  illustrates a cross sectional view of an alternate embodiment of a substrate including a protruding feature formed using the molding tool previously described; 
         FIG. 18  illustrates a top view of an embodiment of a molding tool having several molding members used to simultaneously form several protruding features to a substrate, in accordance with the described embodiments; 
         FIG. 19  illustrates an isometric view of showing an exterior region of an electronic device having several protruding features configured to illuminate via the electronic device; and 
         FIG. 20  illustrates a flowchart showing a method for forming a protruding feature to an electronic device. 
     
    
    
     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 an electronic device. In particular, the disclosure relates to protruding features, sometimes referred to as “feet,” located on a substrate that is part the enclosure. The protruding features may be designed to engage a surface (e.g., table, desk) on which the electronic device lies. Accordingly, the substrate may be associated with a bottom, or lower, region of the enclosure. Further, the substrate may be formed from metal (e.g., aluminum) that receives one or more protruding features. The substrate includes an interior region associated within an internal surface that is generally not visible when the electronic device is fully assembled. The substrate may further include an exterior region associated with an exterior surface that is generally visible when the electronic device is fully assembled. The protruding features generally extend from the exterior region of the substrate. 
     In order to improve integration of the protruding features to the substrate, the substrate may include certain features. For example, the substrate may include several micro-perforations that extend through the bottom region. In other words, the micro-perforations may be referred to relatively small apertures, or micro-apertures, with each aperture including an opening in the interior region of the substrate and an opening in the exterior region of the substrate. The micro-perforations are generally formed in locations of the substrate to which the protruding features are assembled. Also, each of the micro-perforations may include an opening having a diameter on the order of several microns. For instance, the diameter may be approximately in the range of 15-50 microns. In order to form the micro-perforations, a laser ablation tool may be used. The laser ablation tool is positioned relative to the substrate such that the substrate initially receives a laser beam (from the laser ablation tool) on the interior region. In this manner, any residual effects (e.g., burning, charring) are visible only on the interior region that is not visible when the electronic device is assembled, and the (visible) exterior region remains free of the residual effects. Also, once the laser ablation tool forms the aperture or cavity and extends through to the exterior region to form an opening in the exterior region, the resultant openings in the exterior region combine to define a roughness that is approximately similar to that of the remaining exterior region not associated with the openings. This includes instances of altered roughness of the exterior region due processes such as anodization, which in some cases, incorporates placing the substrate in an acidic bath. Further, in some cases, each micro-perforation may include a conical shape. In other words, the opening in the interior region may be larger (e.g., larger diameter) than the opening in the exterior region. As a result, the openings in the exterior regions may be small enough so as to be minimally visible, or even not visible, by the human eye. 
     A molding tool having a molding cavity may be used to form the protruding features. The molding tool is designed to emit a liquid that, when cured, is hardened and defines the shape of the protruding feature. The liquid is capable of passing through the micro-perforations and into the mold cavity. Also, the molding tool is positioned, relative to the substrate, to emit the liquid initially to the interior region of the substrate, thereby allowing the liquid to extend through the micro-perforations and exit through the exterior region. In this manner, protruding features form several mechanical interlocks with the substrate, particularly when the micro-perforations include the conical shape (described above). The molding tool is configured to emit sufficient liquid such that at liquid remain embedded in the micro-perforations. In these locations, the protruding feature, when cured from the liquid form, include a shape corresponding to the shape of the conical micro-perforations. Accordingly, the cured protruding features include a shape that defines several features larger than the opening in the exterior region of the substrate. This feature defines a mechanical interlock between the substrate and the protruding feature. The mechanical interlock may offer superior mechanical coupling over adhesively securing protruding features or simple molding of a protruding feature onto an exterior region of a substrate. 
     The liquid polymer may be made from silicone or a silicone-based material. Generally, any curable liquid may be used that includes a relatively low viscosity that allows the liquid to flow through the micro-perforations. Testing shows that liquid polymer having a viscosity of 950,000 centipoise (“cP”) passed through micro-perforations. However, a “low viscosity” or “relatively low viscosity” liquid polymer may include a viscosity in a range below 950,000 cP. This allows the silicone material in liquid form to pass more readily and easily through the micro-perforations. Further, the liquid selected for the protruding features should be designed to cure at relatively low temperatures. For example, the liquid may cure at a temperature at or below 80 degrees Celsius. In this manner, the regions associated with the micro-perforations do not include a coefficient of thermal expansion significantly different from other regions of the substrate. The cured protruding feature may include a hardness in the “A” range, according to a durometer, which corresponds to a “hard rubber.” Also, the liquid, and therefore the protruding features, can include an opaque material or materials, or alternatively, a translucent material or materials. In the latter case, the electronic device may include a light source (e.g., light emitting diode, light guide panel) configured to emit light through the micro-perforations visible to a user of the electronic device that includes the protruding features. 
     These and other embodiments are discussed below with reference to  FIGS. 1-20 . 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 an electronic device  100 . In some embodiments, the electronic device  100  is a portable computing device. The electronic device  100  may include an enclosure  102  formed from a metallic material (e.g., aluminum). The enclosure  102  may include a lid region  104  that receives a display panel  106  designed to emit visual content to a user. The enclosure  102  may further include a base region  108  that includes several internal components (not shown) enclosure by a top case  110  and a bottom case  112 . The bottom case  112  may include several protruding features (not shown) integrated with the bottom case  112  such that when the electronic device  100  is positioned on a surface (e.g., desk), only the protruding features of the electronic device  100  engage the surface. 
       FIG. 2  illustrates an isometric view of an alternate embodiment of an electronic device  200 . In some embodiments, the electronic device  200  is a tablet computing device. The electronic device  200  may include an enclosure  202  formed from a metallic material (e.g., aluminum). The enclosure  202  may be designed to receive a display panel  206  designed to emit visual content to a user. The enclosure  202  may further include a bottom region  208  that includes protruding features (not shown) integrated with the bottom region  208  such that when the electronic device  200  is positioned on a surface (e.g., desk), only the protruding features of the electronic device  200  engage the surface. 
       FIG. 3  illustrates an isometric view of a substrate  300  that may be part of a base, or lower region, of an electronic device, in accordance with the described embodiments. In some embodiments, the substrate  300  is part of a bottom case  112  (shown in  FIG. 1 ). In other embodiments, the substrate  300  is part of a bottom region  208  of the enclosure  202  (shown in  FIG. 2 ). Still, in other embodiments, the substrate  300  is part of a standalone keyboard (not shown). In either case, the substrate  300  is also formed from the same material or materials as that of the bottom case  112  or bottom region  208 , depending on the electronic device chosen. In some embodiments, the substrate  300  includes several protruding features. For example, the substrate  300  may include two or more protruding features. In the embodiment shown in  FIG. 3 , the substrate  300  includes a protruding feature  302 . Also, as shown in  FIG. 3 , the protruding feature  302  is generally located in a corner region of the substrate  300 . However, the protruding feature  302  may be formed in any location on the substrate  300 . For example, the protruding feature  302  may be positioned proximate to a first dimension  316  (e.g., width) and/or a second dimension  318  (e.g., length) of the substrate  300 . Also, in some embodiments, the protruding feature  302  includes a polygonal shape having three or more sides or edge. However, in the embodiment shown in  FIG. 3 , the protruding feature  302  is generally circular or round and may include an exterior cosmetic surface suitable for consumer electronics. Further, the protruding feature  302  may include a shape that is representative of the remaining protruding features of the substrate  300 . 
     The substrate  300  may include an interior region  310  and an exterior region  312  opposite the exterior region  312 , with the interior region  310  and the exterior region  312  separated by a thickness  314  of the substrate  300 . The interior region  310  is associated with an internal surface of the substrate  300 . Generally, the interior region  310  is not visible when the electronic device is assembled. The exterior region  312  is associated with an exterior surface and is generally visible when the electronic device is assembled. The exterior region  312  may also be referred to as a cosmetic surface that ideally includes an aesthetic appearance. Accordingly, the protruding features generally extend outward with respect to the exterior region  312 . 
     The protruding features shown in  FIG. 3  may be used for one or more purposes. For example, the protruding features may be configured to engage a surface on which the electronic device lies. This may prevent or reducing scratching or other damage to the electronic device. Also, the protruding features may include a coefficient of friction between the electronic device and the surface such that the electronic device is less prone to sliding or moving in an undesired manner. 
       FIGS. 4 and 5  illustrate side views of a substrate  350  in accordance with the described embodiments, to show additional properties of the protruding features. For example, several protruding features of the substrate  350  are designed to be cured and mechanically coupled with the substrate  350  of an electronic device to provide the electronic device with a substantially level configuration when the substrate  350  is engaged with a surface  380 . 
       FIG. 4  illustrates a side view of a substrate  350  along the first dimension  366  of the substrate  350  showing a first protruding feature  352  and a second protruding feature  354  lying on the surface  380 .  FIG. 5  illustrates an alternate side view of the substrate  350  along the second dimension  368  of the substrate  350  with the second protruding feature  354  and a third protruding feature  356  lying on the surface  380 .  FIGS. 4 and 5  combine to show that the substrate  350  can include multiple protruding features, the formation of which is described herein, that allow an electronic device that includes the substrate  350  to be substantially level or at least substantially parallel to the surface  380 . Also, the protruding features may combine to define a clearance  360  between the exterior region  362  and the surface  380 . In this manner, the substrate  350  may be free of contact with the surface  380 . 
       FIG. 6  illustrates a plan view of an interior region  410  of a substrate  400  that includes multiple regions of apertures extending through the substrate  400 , in accordance with the described embodiments. The apertures, as shown, may be referred to as micro-apertures. As shown, the substrate  400  includes a region  402  of apertures. The apertures in these regions may be formed within the substrate  400  using a laser ablation tool (shown later). For purposes of illustration, an enlarged view of a portion of the region  402  of apertures is shown, with the region  402  having an aperture  420  (representative of other apertures in the substrate  400 ) with an opening  422  having a first diameter  424  on the interior region  410 . Due to its relatively small size, the aperture  420  may also be referred to as a micro-aperture. 
       FIG. 7  illustrates a plan view of the substrate  400  shown in  FIG. 6 , oriented to show an exterior region  412  of the substrate  400 . The exterior region  412  is associated with a surface opposite to that of the interior region  410  (shown in  FIG. 6 ). The regions of several apertures extend through the substrate  400 , and accordingly, the region  402  of apertures extend to the exterior region  412 . However, as seen from the exterior region  412 , the regions of multiple apertures (depicted in gray) are less visible, and in some cases, not visible to the human eye. This may be due in part to the laser ablation tool forming an aperture initially through the interior region  410  (in  FIG. 6 ) such that any residue remains in the interior region  410 . Further, the laser ablation tool may form the apertures such that the apertures are conical. In other words, the apertures include openings on the exterior region  412  that are smaller than openings on the interior region  410 . For example, in the enlarged view of a portion of the region  402  of apertures shown in  FIG. 7 , the aperture  420  (also shown in  FIG. 6 ) includes an opening  426  having a second diameter  428  on the exterior region  412  that is less than the first diameter  424  on the interior region  410 . 
     Also, in some embodiments, the apertures are formed in an ordered (non-randomized) manner. In those embodiments, adjacent apertures within each region are spaced apart a distance approximately in the range of 150-200 microns. However, in the embodiment shown in  FIGS. 6 and 7 , the apertures are generally in a randomized pattern. Also, it will be appreciated that the size of the apertures and the distance between adjacent apertures may not be drawn to scale. Further, in some embodiment, the substrate  400  includes several regions of apertures similar to the region  402  of apertures, and having similar proportional diameters in the interior region  410  and the exterior region  412 . For example, the several regions of apertures may be positioned in each corner regions of the substrate  400  shown in  FIGS. 6 and 7 . 
     Although the apertures shown in  FIGS. 6 and 7  combine to generally form a circular region of apertures, other configurations of apertures may be used. For example,  FIG. 8  illustrates enlarged view showing a portion of an interior region  510  of a substrate  500  having an alternate pattern of several apertures extending through the substrate  500 , in accordance with the described embodiments. The apertures, as shown, may be referred to as micro-apertures. The substrate  500  includes a region  502  of apertures, or openings, having a first region  504  of apertures, or openings, in a ring like manner surrounding a second region  506  of apertures, or openings, with the second region  506  generally having a circular configuration. The first region  504  and the second region  506  may contribute to a molding technique of a protruding feature (not shown) and will be discussed in detail below. Also, the substrate  500  may include several other regions of apertures having a similar configuration as that of the region  502  of apertures. 
       FIG. 9  illustrates an enlarged plan view of the substrate  500  shown in  FIG. 8 , oriented to show the exterior region  512  of the substrate  500 . As shown, the region  502  of apertures extends to the exterior region  512 . However, at least some of the apertures may include an opening having a diameter on the exterior region  512  less than a diameter of the corresponding opening on the interior region  510 . Accordingly, the openings on the exterior region  512  (depicted in gray) may be less visible, and in some cases, not visible to the human eye. 
       FIG. 10  illustrates a cross sectional view of the substrate  500  shown in  FIG. 8 , taken along the  10 - 10  line. As shown, the substrate  500  includes several apertures that may be formed by a laser ablation tool  580 . Also, in some embodiments, the laser ablation tool  580  is positioned with respect to the substrate such that the interior region  510  initially receives the laser beam  582  used to form the apertures. For example, as shown in  FIG. 10 , the laser ablation tool  58  forms an aperture  514  of the first region  504  of apertures by first ablating from the interior region  510  and then to the exterior region  512 . Further, the laser ablation tool  580  may be configured, or tuned, to form apertures of different shapes and dimensions. For example, in some embodiments (not shown) the laser ablation tool  580  form substantially cylindrical apertures through the substrate  500 , with a representative aperture including an opening in the interior region that is substantially similar in size (including cross sectional area) as comparted to an opening in the exterior region. Also, in some embodiments, the fluid material used to form a protruding feature is relatively viscous (e.g., thermoplastic polyurethane). In those embodiments, the laser ablation tool  580  is capable of forming apertures having larger dimensions than those shown in  FIG. 10  such that the relatively high viscous materials may nonetheless flow through the apertures. 
     Despite the laser ablation tool  580  forming an aperture from the interior region  510  to the exterior region  512  of the substrate  500 , a roughness or texture may form on the exterior region  512 . Also, in some embodiments, an enclosure of an electronic device, which includes the substrate  500 , undergoes an anodization process designed to provide an improved strength and appearance, as well as improved resistance to scratching of the enclosure. This may change or alter the roughness or texture of the substrate  500 . However, the exterior region  512  may nonetheless include a roughness or texture from the resultant laser ablation that is substantially similar to the roughness or texture in other regions of the substrate  500  subsequent to the anodization process. 
       FIG. 10  further illustrates an enlarged view of the substrate  500  in the first region  504  having an aperture  516  representative of other apertures in the substrate  500 . Due to its relatively small size, the aperture  516  may also be referred to as a micro-aperture. The laser ablation tool  580  is designed to form the aperture  516  such that the aperture  516  includes a first opening  518  in the interior region  510  and a second opening  520  on the exterior region  512 , with the second opening  520  smaller than the first opening  518 . Also, the laser ablation tool  580  forms a channel  524  through the substrate  500  that connects the first opening  518  with the second opening  520 . Accordingly, the second opening  520  may include a second diameter  530  less than a first diameter  528  of the first opening  518  to define an aperture  516  having a conical shape. In this manner, when a liquid flows through the apertures having a similar configuration as that of aperture  516 , the liquid may cure or harden within the apertures. In some embodiments, the first diameter  528  of the first opening  518  is approximately 30 microns. However, in some embodiments, the first diameter  528  is less than 30 microns. Accordingly, the second diameter  530  is smaller to maintain a similar relationship with respect to the first diameter  528 , i.e., the second diameter  530  remains smaller than the first diameter  528 . Also, based upon the generally circular configuration of the first opening  518  and the second opening  520  and the relationship of the diameters, the first opening  518  includes a first cross sectional area and the second opening  520  includes a second cross sectional area less than the first cross sectional area. The protruding feature may include cured material within the apertures and extending from the exterior region  512  to a location proximate to, or above, the interior region  510 . In this manner, the portions of the protruding feature proximate to the interior region  510  include a shape that is larger than the second opening  520  (or the second diameter  530 ), thereby providing the protruding feature mechanically interlocked to the substrate  500 . 
       FIG. 11  illustrates a cross sectional view of alternate embodiment of a portion of a substrate  550 , in accordance with the described embodiments. The substrate  550  may include a region (similar to the region  502  in  FIGS. 8 and 9 ) having a first region  554  of apertures surrounding a second region  556  of apertures. However, in this embodiment, the substrate  550  may include additional portion removed by a material removal process to define a first indention  564  extending around a second indention  566 . The first indention  564  and the second indention  566  may be used to receive additional fluid material to form a protruding feature. The first indention  564  and the second indention  566  may designed to ensure a location above the interior region  560  (in a z-direction) is free of any material used to form the protruding feature. In this manner, any protruding feature mechanically coupled to the substrate  550  does not interfere with internal components of an electronic device that includes the substrate  550 . 
       FIG. 12  illustrates a partial cross sectional view of the substrate  500  shown in  FIG. 10 , with a cross section of a molding tool  600  configured to mold a protruding feature to the substrate  500 , in accordance with the described embodiments. In some embodiments, the molding tool  600  is an injection molding tool capable of injection molding material to a substrate. Also, in some embodiments, the molding tool  600  includes a first chamber  604  and a second chamber  606 . Generally, the first chamber  604  and the second chamber  606  are configured to align with regions of apertures. For example, the first chamber  604  and the second chamber  606  are aligned with the first region  504  of apertures, and designed to fill the first region  504  of apertures with a shot (or multiple shots) of material in fluid form used to form a protruding feature. Also, the first chamber  604  and the second chamber  606  are positioned proximate to the interior region  510  such that the material in fluid form first enters the first region  504  of apertures via the interior region  510 . The material in fluid form may extend through the first region  504  of apertures and into a mold cavity  608  positioned proximate to the exterior region  512  of the substrate. The mold cavity  608  includes a shape that corresponds to a shape, or internal cavity, that defines a shape of the protruding feature. The mold cavity  608  generally includes a three-dimensional, dome-shaped configuration. However, the mold cavity  608  may embody additional three-dimensional shapes or features. Further, the mold cavity  608  may include a flat, non-rounded configuration to define a flat, non-rounded region of a protruding feature. 
       FIG. 13  illustrates the partial cross sectional view of the substrate  500  and the molding tool  600  shown in  FIG. 12 , showing the molding tool  600  filling the substrate  500  with a material  700  in fluid form used to form the protruding feature. The material  700  flows through the first chamber  604  and the second chamber  606  to enter the first region  504  of apertures. Accordingly, the first region  504  of apertures defines a gate through which the material  700  flows. The gate may also be referred to as a channel region  508  that extends through the substrate  500  to allow the material  700  to pass through the substrate  500 . Once the material  700  flows through the first region  504 , the material  700  continues into the mold cavity  608 . 
     In some embodiments, the material  700  is a silicon-based material. In other embodiments, the material  700  is a urethane acrylate material. Also, in some embodiments, the material  700  is opaque (or cures to form an opaque structure). Still, in other embodiments, the material  700  liquid silicone rubber. Further, in other embodiments, the material  700  is two-part epoxy, or two-part resin, that includes a liquid hardener that may be added to a liquid resin. Generally, the material  700  can be any liquid injection moldable polymer known in the art for injection molding. In this regard, the material  700  can cure to define a polymer feature, or polymeric feature, designed as a protruding feature. Also, in some embodiments, the material  700  is opaque. In the embodiment shown in  FIG. 13 , the material  700  is transparent. Also, the material  700  is translucent. Further, the material  700  is designed to cure at a temperature of 80 degrees Celsius or less. In this manner, a coefficient of thermal expansion of the substrate  500  in the first region  504  of apertures is not substantially different from a coefficient of thermal expansion of remaining regions of the substrate  500 . As a result, the substrate  500  is less susceptible to damage, such as cracking. 
       FIG. 14  illustrates the partial cross sectional view of the substrate  500  and the molding tool  600  shown in  FIG. 13 , showing the molding tool having filled the mold cavity  608  of the molding tool  600  with the material  700  used to form the protruding feature. In some cases, the material  700  may include gas molecules  702  defining bubbles in the material  700  that are undesirable. However, prior to curing the material  700 , the molding tool  600  is designed to remove the gas molecules  702  from the material  700 . 
       FIG. 15  illustrates the partial cross sectional view of the substrate  500  and the molding tool  600  shown in  FIG. 14 , showing the molding tool  600  using a vacuum  610  to remove the gas molecules  702  from the material  700  used to form the protruding feature. The vacuum  610  is designed to align with the second region  506  of apertures in the substrate  500 . By allowing the gas molecules  702  to escape from the material  700 , the material  700  can cure to form a protruding feature having a uniform density. In this configuration, the vacuum  610  acts as a venting apparatus and is configured for use proximate to the interior region  510  of the substrate  500  as shown in  FIG. 15 . Therefore, a separate venting apparatus on the exterior region  512  is not required. This may result in greater efficiency as well as keeping the (cosmetic) exterior region  512  free of tooling resulting in a lower probability of damage to the exterior region  512 . 
       FIG. 16  illustrates a cross sectional view of a protruding feature  710  formed using the molding tool previously described, in accordance with the described embodiments. It will be appreciated that the protruding feature  710  has undergone a curing process such that the material  700  (in  FIG. 15 ) is no longer in a liquid form. As shown, the protruding feature  710  is mechanically coupled to the substrate  500 . In particular, the protruding feature  710  includes several features, such as a first feature  712  and a second feature  714 , that are larger the openings in the exterior region  512  of the substrate. For example, the second feature  714  includes a diameter  724  at the interior region  510  greater than the second diameter  530  of the second opening  520  (of the aperture  516 ) at the exterior region  512  of the substrate  500 . This configuration defines a mechanical interlock between the protruding feature  710  and the substrate  500 . Also, it will be understood that the protruding feature  710  is a representative protruding feature and several protruding features may be mechanically interlocked to the substrate  500  in a similar manner. Also, in instances when the protruding features are formed from polymeric material, the protruding features may also be referred to as a polymer feature. 
       FIG. 17  illustrates a cross sectional view of an alternate embodiment of a substrate  750  including a protruding feature  760  formed using the molding tool  600  previously described. In this embodiment, the protruding feature  760  includes a flat region  762  that is generally straight, that is, not rounded. Accordingly, a mold cavity (not shown) may include a flat region corresponding to the flat region  762  to form the protruding feature  760  shown in  FIG. 17 . 
       FIG. 18  illustrates a top view of an embodiment of a molding tool  800  having several molding members used to simultaneously form several protruding features to a substrate  900 , in accordance with the described embodiments. As shown, the molding tool  800  is positioned over a substrate  900  having several regions of apertures, such as a region  902  of apertures. The molding tool  800  may include any feature or features previously described for a molding tool. Also, the molding tool  800  is designed to include a similar number of mold members as the number of protruding features to be molded to the substrate  900 , with the mold members positioned over the regions of apertures. For example, the molding tool  800  in  FIG. 18  a first mold member  802  positioned over a region  902  of apertures of the substrate  900 . However, in other embodiments with two or more regions of apertures, the molding tool  800  includes a corresponding number of mold members. Also, the molding tool  800  may include a mold cavity (not shown) positioned proximate to a surface of substrate  900  opposite the surface shown in  FIG. 18 . Further, the mold cavities may be located proximate to the regions of apertures to receive a material from the molding tool  800  used to form protruding features. 
     Each mold member may include one or more chambers configured to deliver a shot (or multiple shots) of a material in fluid form to each region of apertures of the substrate  900 . Also, each mold member may include a vacuum to remove gas molecules within the material in fluid form. Accordingly, multiple protruding features can be formed on the substrate  900  using a molding tool  800  with multiple mold members. 
       FIG. 19  illustrates an isometric view of showing a bottom region of an electronic device  1000  having several protruding features configured to illuminate via the electronic device  1000 . In some embodiments, the electronic device  1000  is a portable computing device (similar to  FIG. 1 ) in a closed configuration. As shown, the electronic device  1000  includes a first protruding feature  1002 , a second protruding feature  1004 , a third protruding feature  1006 , and a fourth protruding feature  1008 . The protruding features are mechanically interlocked with the exterior region  1012  of the enclosure  1020  of the electronic device  1000  in a manner previously described for a protruding feature. Also, the protruding features are formed from a translucent material. In this manner, each of the protruding features may illuminate via a light source (not shown) within the electronic device  1000 . The light source emits light capable of extending through the regions of apertures through which a portion of the protruding features are positioned. 
     The illumination of the protruding features may provide an indication of the electronic device  1000  to a user. For example, at least one of the first protruding feature  1002 , the second protruding feature  1004 , the third protruding feature  1006 , and the fourth protruding feature  1008  may illuminate to indicate the electronic device  1000  is in a “standby” or “sleep” mode, both of which are associated with a low-power mode and/or a period of inactivity of the electronic device  1000 . Further, at least one of the protruding features may illuminate to green, for example, when an internal power supply (e.g., battery) of the electronic device  1000  is fully charged. Also, at least one of the protruding features may illuminate to yellow or red to illuminate to indicate a medium and low charge, respectively, of the internal power supply. Alternatively, the user may configure the protruding features to illuminate for other desired purposes, and may select, using the electronic device  1000 , another color or colors for indication. 
       FIG. 20  illustrates a flowchart  1100  showing a method for forming a polymer feature to a substrate having an interior region and an exterior region opposite the interior region. The substrate may be part of an enclosure, such as a bottom case, of an electronic device. In step  1102 , a material in fluid form is sent through a first micro-aperture using a molding tool. In some embodiments, the first micro-aperture is formed in the substrate and include a first opening disposed on the interior region of and a second opening disposed on the exterior region. In some embodiments, the first opening includes a size and a cross sectional area similar to that of the second opening. In other embodiments, the first opening includes a size and a cross sectional area different from the second opening. For example, the first opening may include a size and a cross sectional area greater than that of the second opening. Also, the first opening may be connected with the second opening via a channel formed through the substrate. Also, the first micro-aperture may be part of several micro-apertures may be formed in the substrate. Each of the several micro-apertures may be formed using a laser ablation tool. The laser ablation tool may form each of the micro-apertures with an opening in the interior region approximately in the range of 15 to 50 microns. Also, the laser ablation tool may form conical micro-apertures such that the opening in the interior region is larger than the opening in the exterior region. In other words, the first opening may be greater than that of the second opening. 
     In step  1104 , material is received from the channel at the exterior region via the second opening. Some of the material may remain within the channel. However, the material may further flow into a mold cavity that includes an internal cavity having a shape that defines the feature to be formed. 
     In an optional step  1106 , gas may be removed from the material at the second micro-aperture. The second micro-aperture may include a first opening disposed on the interior region, a second opening disposed on the exterior region, and a channel that opens to the first opening and the second opening. When the material in fluid form cures, it becomes a hardened material that defines a protruding feature. Also, the fluid remaining within the first micro-aperture and the second-micro aperture cures to define a mechanical interlock between the feature and the substrate. 
     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: 20150731
Publication Date: 20180306
Grant Date: 20180306
Priority Date: 20141112
Inventors: GARELLI ADAM T.
LANCASTER-LAROCQUE SIMON REGIS LOUIS
MATHEW DINESH C.
BERG BRUCE E.
MONTPLAISIR SARAH J.
RUNDLE NICHOLAS A.
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C45/34", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14344", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2045/14352", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/34", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29K2033/08", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/14368", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2019/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/14352", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2019/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14344", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/34", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2033/08", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/14368", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/34", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 55963045