PATENT DOCUMENT

Publication Number: US-9185835-B2
Application Number: US-201313746603-A
Country: US
Kind Code: B2

Title: Techniques for marking product housings

Abstract:
Techniques or processes for providing markings on products are disclosed. The markings provided on products can be textual and/or graphic. The techniques or processes can provide high resolution markings on surfaces that are flat or curved. In one embodiment, the products have housings and the markings are to be provided on the housings. For example, the housing for a particular product can include an outer housing surface and the markings can be provided on the outer housing surface.

Claims:
What is claimed is:  
     
       1. A method for depositing material to selected regions of an electronic device housing, said method comprising:
 adhering a photoresist layer to a housing surface of the electronic device housing; 
 positioning a masking film over the photoresist layer that is adhered to the housing surface, the masking film including a predetermined pattern; 
 exposing the masking film and the photoresist layer to radiation, thereby exposing a portion of the photoresist layer in accordance with the predetermined pattern; 
 removing the masking film from proximity of the photoresist layer; 
 removing the portion of the photoresist layer that has been exposed; 
 depositing a layer of material onto the housing surface, the layer of material being provided on the housing surface where the portion of the photoresist layer has been removed and being provided on a remaining portion of the photoresist layer; and 
 removing the remaining portion of the photoresist layer and the portion of the layer of material provided on the remaining portion of the photoresist layer, thereby retaining the layer of material on the housing surface in accordance with the predetermined pattern, 
 wherein the layer of material is a layer of metal, and 
 wherein the layer of material retained on the housing surface in accordance with the predetermined pattern serves to mark the housing surface of the electronic device housing. 
 
     
     
       2. A method as recited in  claim 1 , wherein the predetermined pattern is transparent in the selected regions where the material is to be deposited. 
     
     
       3. A method as recited in  claim 1 , wherein the photoresist layer includes at least a UV photoresist material, and wherein the radiation is UV radiation. 
     
     
       4. A method as recited in  claim 1 , wherein said method further comprises:
 subsequently applying a translucent protective layer to the housing surface. 
 
     
     
       5. A method as recited in  claim 1 , wherein the material retained on the housing surface in the predetermined pattern includes text and graphics. 
     
     
       6. A method as recited in  claim 1 , wherein the material retained on the housing surface in the predetermined pattern includes at least one graphic, the at least one graphic being a logo, a certification mark or an approval mark. 
     
     
       7. A method as recited in  claim 1 , wherein the layer of material is applied by Physical Vapor Deposition. 
     
     
       8. A method as recited in  claim 7 , wherein the layer of metal is a layer of silver. 
     
     
       9. A method as recited in  claim 1 , wherein the housing surface is an outer housing surface. 
     
     
       10. A method as recited in  claim 1 , wherein at least the portion of the housing surface of the electronic device housing being marked has a curvature. 
     
     
       11. A method as recited in  claim 1 , wherein the electronic device housing is a handheld, portable electronic device, and wherein the housing surface is an outer housing surface. 
     
     
       12. A method as recited in  claim 11 , wherein the material retained on the housing surface in the predetermined pattern includes text and graphics. 
     
     
       13. A method as recited in  claim 11 , wherein the material retained on the housing surface in the predetermined pattern includes at least one graphic, the at least one graphic being a logo, a certification mark or an approval mark. 
     
     
       14. A method as recited in  claim 11 , wherein the layer of material is applied by Physical Vapor Deposition (PVD). 
     
     
       15. A method for depositing material to selected regions of an electronic device housing, said method comprising:
 adhering a photoresist layer to a housing surface of the electronic device housing; 
 positioning a mask over the photoresist layer that is adhered to the housing surface, the mask including a predetermined pattern; 
 exposing the mask and the photoresist layer to radiation, thereby exposing a portion of the photoresist layer in accordance with the predetermined pattern; 
 removing the mask from proximity of the photoresist layer; 
 removing the portion of the photoresist layer that has been exposed; 
 depositing a layer of material onto the housing surface, the layer of material being provided on the housing surface where the portion of the photoresist layer has been removed and being provided on a remaining portion of the photoresist layer; and 
 removing the remaining portion of the photoresist layer and the portion of the layer of material provided on the remaining portion of the photoresist layer, thereby retaining the layer of material on the housing surface in accordance with the predetermined pattern, 
 wherein the layer of material retained on the housing surface in accordance with the predetermined pattern serves to mark the housing surface of the electronic device housing, and 
 wherein the electronic device housing is a handheld, portable electronic device. 
 
     
     
       16. A method as recited in  claim 15 , wherein the electronic device housing is a handheld, portable electronic device, and wherein the housing surface is an outer housing surface. 
     
     
       17. A method as recited in  claim 16 , wherein the material retained on the housing surface in the predetermined pattern includes text and graphics. 
     
     
       18. A method as recited in  claim 16 , wherein the material retained on the housing surface in the predetermined pattern includes at least one graphic, the at least one graphic being a logo, a certification mark or an approval mark. 
     
     
       19. A method as recited in  claim 16 , wherein the layer of material is applied by Physical Vapor Deposition (PVD). 
     
     
       20. A method for depositing material to selected regions of an electronic device housing, said method comprising:
 adhering a photoresist layer to a housing surface of the electronic device housing; 
 positioning a mask over the photoresist layer that is adhered to the housing surface, the mask including a predetermined pattern; 
 exposing the mask and the photoresist layer to radiation, thereby exposing a portion of the photoresist layer in accordance with the predetermined pattern; 
 removing the mask from proximity of the photoresist layer; 
 removing the portion of the photoresist layer that has been exposed; 
 depositing a layer of material onto the housing surface using Physical Vapor Deposition (PVD), the layer of material being provided on the housing surface where the portion of the photoresist layer has been removed and being provided on a remaining portion of the photoresist layer; and 
 removing the remaining portion of the photoresist layer and the portion of the layer of material provided on the remaining portion of the photoresist layer, thereby retaining the layer of material on the housing surface in accordance with the predetermined pattern. 
 
     
     
       21. A method as recited in  claim 20 , wherein the layer of material retained on the housing surface in accordance with the predetermined pattern serves to mark the housing surface of the electronic device housing. 
     
     
       22. A method as recited in  claim 21 , wherein the electronic device housing is a handheld, portable electronic device, and wherein the housing surface is an outer housing surface. 
     
     
       23. A method as recited in  claim 22 , wherein the material retained on the housing surface in the predetermined pattern includes text and graphics. 
     
     
       24. A method as recited in  claim 22 , wherein said method further comprises:
 subsequently applying a translucent protective layer to the housing surface. 
 
     
     
       25. A method as recited in  claim 22 , wherein the material retained on the housing surface in the predetermined pattern includes at least one graphic, the at least one graphic being a logo, a certification mark or an approval mark. 
     
     
       26. A method as recited in  claim 22 , wherein the layer of material is a layer of metal.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. patent application Ser. No. 12/475,597, filed May 31, 2009, and entitled “Techniques for Marking Product Housings,” which is hereby incorporated herein by reference. 
     This application, via U.S. patent application Ser. No. 12/475,597, claims priority to U.S. Provisional Patent Application No. 61/059,789, filed Jun. 8, 2008, and entitled “Methods and Systems for Manufacturing an Electronic Device,” which is hereby incorporated herein by reference. 
     This application, via U.S. patent application Ser. No. 12/475,597, claims priority to U.S. Provisional Patent Application No. 61/121,491, filed Dec. 10, 2008, and entitled “Techniques for Marking Product Housings,” which is hereby incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to marking products and, more particularly, marking outer housing surfaces of electronic devices. 
     2. Description of the Related Art 
     Consumer products, such as electronic devices, have been marked with different information for many years. For example, it is common for electronic devices to be marked with a serial number, model number, copyright information and the like. Conventionally, such marking is done with an ink printing or stamping process. Although conventional ink printing and stamping is useful for many situations, such techniques can be inadequate in the case of handheld electronic devices. The small form factor of handheld electronic devices, such as mobile phones, portable media players and Personal Digital Assistants (PDAs), requires that the marking be very small. In order for such small marking to be legible, the marking must be accurately and precisely formed. Unfortunately, however, conventional techniques are not able to offer sufficient accuracy and precision. Thus, there is a need for improved techniques to mark products. 
     SUMMARY 
     The invention pertains to techniques or processes for providing markings on products. The markings provided on products can be textual and/or graphic. The techniques or processes can provide high resolution markings on surfaces that are flat or curved. In one embodiment, the products have housings and the markings are to be provided on the housings. For example, the housing for a particular product can include an outer housing surface and the markings can be provided on the outer housing surface. 
     In general, the markings, or annotations, provided on products according to the invention can be textual and/or graphic. The markings can be used to provide a product (e.g., a product&#39;s housing) with certain information. The marking can, for example, be use to label the product with various information. When a marking includes text, the text can provide information concerning the product (e.g., electronic device). For example, the text can include one or more of: name of product, trademark or copyright information, design location, assembly location, model number, serial number, license number, agency approvals, standards compliance, electronic codes, memory of device, and the like). When a marking includes a graphic, the graphic can pertain to a logo, a certification mark, standards mark or an approval mark that is often associated with the product. The marking can be used for advertisements to be provided on products. The markings can also be used for customization (e.g., user customization) of a housing of a product. 
     One aspect described herein provides product marking using photolithography. Here, intermediate material can be adhered to a product surface, then patterned, and then material that is to be used for marking can deposited onto the product surface. Subsequently, any remaining intermediate material can be removed (along with any intermediate material) such that the product thereafter includes the text and/or graphics for the product marketing 
     Another aspect described herein provides product marking using ablation. Here, material that is to be used for marking is deposited onto a product surface and then ablated to yield the text and/or graphics for the product marketing. 
     The invention can be implemented in numerous ways, including as a method, system, device, or apparatus. Several embodiments of the invention are discussed below. 
     As a method for depositing material to selected regions of an electronic device housing, one embodiment of the invention can, for example, include at least: adhering a photoresist layer to a housing surface of the electronic device housing; positioning a masking film over the photoresist layer that is adhered to the housing surface, the masking film including a predetermined pattern; exposing the masking film and the photoresist layer to radiation, thereby exposing a portion of the photoresist layer in accordance with the predetermined pattern; removing the masking film from proximity of the photoresist layer; removing the portion of the photoresist layer that has been exposed; depositing a layer of material onto the housing surface, the layer of material being provided on the housing surface where the portion of the photoresist layer has been removed and being provided on a remaining portion of the photoresist layer; and removing the remaining portion of the photoresist layer and the portion of the layer of material provided on the remaining portion of the photoresist layer, thereby retaining the layer of material on the housing surface in accordance with the predetermined pattern. 
     As a method for depositing material to selected regions of an electronic device housing, another embodiment of the invention can, for example, include at least: forming a mask layer having at least one predetermined opening; adhering the mask layer to an housing surface of the electronic device housing; depositing a layer of material onto the housing surface, the layer of material being provided on the housing surface at least within the predetermined opening of the mask layer; removing the mask layer from the outer surface housing; and removing select portions of the layer of material that are not desired to remain on the outer surface housing. 
     As a method for depositing material to selected regions of an electronic device housing, another embodiment of the invention can, for example, include at least: depositing a layer of material onto an housing surface of the electronic device housing; and performing laser ablation of select portions of the layer of material on the housing surface to thereby remove the select portions of the of the layer of material that are not desired to remain on the outer surface housing. 
     As a method for depositing material to selected regions of an electronic device housing, still another embodiment of the invention can, for example, include at least: forming a mask on a housing surface of the electronic device housing, the mask having a predetermined pattern; depositing a layer of material onto the housing surface, the layer of material being provided on the housing surface where the mask has openings; and subsequently removing the mask from the housing surface, thereby retaining the layer of material on the housing surface in accordance with the predetermined pattern. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  is a process flow diagram for product marking process according to one embodiment of the invention. 
         FIGS. 2A-2H  are diagrams detailing a product marking process according to one embodiment of the invention. 
         FIGS. 3A-3H  are diagrams detailing a product marking process according to another embodiment of the invention. 
         FIG. 4  is a process flow diagram for a product marking process according to another embodiment of the invention. 
         FIGS. 5A-5E  are diagrams detailing a product marking process according to one embodiment of the invention. 
         FIGS. 6A and 6B  are diagrams illustrating exemplary marking of a product in accordance with a product marking process. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The invention pertains to techniques or processes for providing markings on products. The markings provided on products can be textual and/or graphic. The techniques or processes can provide high resolution markings on surfaces that are flat or curved. In one embodiment, the products have housings and the markings are to be provided on the housings. For example, the housing for a particular product can include an outer housing surface and the markings can be provided on the outer housing surface. 
     In general, the markings, or annotations, provided on products according to the invention can be textual and/or graphic. The markings can be used to provide a product (e.g., a product&#39;s housing) with certain information. The marking can, for example, be use to label the product with various information. When a marking includes text, the text can provide information concerning the product (e.g., electronic device). For example, the text can include one or more of: name of product, trademark or copyright information, design location, assembly location, model number, serial number, license number, agency approvals, standards compliance, electronic codes, memory of device, and the like). When a marking includes a graphic, the graphic can pertain to a logo, a certification mark, standards mark or an approval mark that is often associated with the product. The marking can be used for advertisements to be provided on products. The markings can also be used for customization (e.g., user customization) of a housing of a product. 
     Embodiments of the invention are discussed below with reference to  FIGS. 1-6B . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. 
     One aspect described herein provides product marking using photolithography. Here, an intermediate material can be adhered to a product surface, then patterned, and then material that is to be used for marking can deposited onto the product surface. Subsequently, any remaining intermediate material can be removed (along with any of the material used for marking that is provided therein) such that the product thereafter includes the text and/or graphics for the product marketing in accordance with the patterned intermediate material. 
       FIG. 1  is a process flow diagram for product marking process  100  according to one embodiment of the invention. The product marking process  100  is, for example, suitable for applying text or graphics to a housing surface (e.g., an outer housing surface) of an electronic device. The product marking process  100  is, in one embodiment, particularly well-suited for applying text and/or graphics to an outer housing surface of a handheld electronic device. Examples of handheld electronic devices include mobile telephones (e.g., cell phones), Personal Digital Assistants (PDAs), portable media players, remote controllers, pointing devices (e.g., computer mouse), game controllers, etc. 
     The product marking process  100  operates to mark an outer housing surface of an electronic device. The product marking process  100  is a multi-step process to form high resolution text or graphics onto the outer housing surface. The outer housing surface can be flat or curved. 
     Initially, the product marking process  100  adheres  102  a photoresist layer to an outer housing surface. In effect, the photoresist layer is laminated against the outer housing surface (since the outer housing surface is to carry the marking). In one implementation, to ensure that the photoresist layer is tightly sealed against the outer housing surface (at least in the area being processed), one or more heated, conformable rollers can be used to apply heat and pressure. The conformable nature of the one or more roller is advantageous when the outer housing surface is curved. In this embodiment, the masking film can be a dry film photoresist. In an alternative embodiment, the masking film can be a wet film photoresist, which can be positioned  104  on the photoresist layer using spin-coating. 
     Next, a masking film can be positioned  104  over the photoresist layer on the outer housing surface. The masking film and the photoresist later can then be exposed  106  to radiation. For example, the radiation can be ultraviolet (UV) radiation that is used to activate portions of the photoresist layer. More particularly, the masking film has a predetermined pattern for the text or graphics to be applied to the outer housing surface. Hence, by applying the masking film over at the photoresist layer, only selected portions of the photoresist layer are activated by the radiation. In other words, the masking film allows the radiation to pass through to activate the photoresist layer in only the selected portions which pertain to the predetermined pattern. For example, the predetermined pattern of the masking film can be considered an inverse stencil in that is serves to block the radiation in regions where marking is not to be provided. In one implementation, the masking film can be a silver-halide thin film. 
     Next, the masking film can be removed  108 . Further, an exposed (i.e., activated) portion of the photoresist layer can be removed  110 . The removal of the photoresist layer by performed by a chemical washing operation. In one implementation, the chemical washing can use a potassium carbonate or sodium carbonate solution. 
     Thereafter, a layer of material can be deposited  112  onto the outer housing surface. For example, the layer of material can be deposited  112  by a deposition process, such as sputtering. One suitable process for the deposition of the layer of material is a Physical Vapor Deposition (PVD) process. The layer of material being deposited can very depending upon application. However, one suitable layer of material is a layer of metal, such as silver. Alternatively, the layer of material can be a layer of tin or other material that can be applied with a deposition process. 
     Next, any remaining photoresist can be removed  114  from the outer housing surface. The layer of material that is deposited on the remaining photoresist is also removed as the underlying photoresist is removed. The removal of the photoresist layer by performed by a chemical washing operation. In one implementation, the chemical washing can use a relatively weak solution of sodium hydroxide (NaOH). 
     Thereafter, if desired, a translucent protective layer can be applied  116  to the outer housing surface so as to cover and protect the remaining layer of material that provides the graphical elements and/or textual elements on the outer housing surface that serve to mark the product. For example, the translucent protective layer can be a layer of acrylic. Following the block  116 , the product marking process  100  can end. 
     In one embodiment, at least a portion of product housing can be formed of a plastic or resin, such as polycarbonate. The marking can use a material that is metal (e.g., silver), which can be reflective. The resulting marking on the product housing is thus able to be provided in high resolution on a product&#39;s housing. 
     In one particular embodiment, the processing parameters for one suitable implementation can, for example, be as follows: 
     Lamination of a photoresist layer to a housing surface 
     Lamination speed: 53 rpm 
     Laminating temp: 100 degrees Celsius 
     Lamination pressure: 5 Kg/cm2 
     Roller hardness: ≦68 
     Pressure uniformity 
     Roller cleaning (with Isopropyl Alcohol), e.g., to prevent press in dents 
     Exposure 
     Exposure Energy: 78 mj/cm2 
     Resist: 1 (e.g., in case of a white housing) 
     Main vacuum: &lt;-700 KPa 
     Phototool Dmax: &gt;4.5 
     Phototool: No Emulsion Protective Layer 
     Exposure vacuum foil: Using clear film Polyethylene Teraphthalate (PET) 
     Change white light to yellow light 
     Avoid scratch and cleaning tray 
     Avoid paint and protect rustiness using tape 
     Cleaning and stick roller 
     Developing 
     Sodium carbonate: 0.8%˜0.9% 
     Break point: 50%˜60% 
     Pressure: 1.8 Kg/cm2 
     Speed: 4.7 m/min (3 dev chamber) 
     Hard Water rinse: 200-250 ppm 
     Rinse (e.g., de-ionized water rinse 
     Stripping 
     1. Sputter silver (Thickness 20 nm)
         Sodium hydroxide: 1.5%   Solution temperature: 50 degrees Celsius   Stripping time: 5′40″˜6′   Stripping time can be reduced with other solutions       

     2. Sputter Aluminum (Thickness 50 nm) 
       FIGS. 2A-2H  are diagrams detailing a product marking process according to one embodiment of the invention. The product marking process shown in  FIGS. 2A-2H  pertains to one embodiment of the product marking process  100  illustrated in  FIG. 1 . 
       FIG. 2A  is a diagram illustrating a housing portion  200 . The housing portion  200  can represent a portion of a product housing, such as an outer housing of an electronic device. 
       FIG. 2B  is a diagram illustrating the housing portion  200  having a photoresist layer  202  applied thereon. 
       FIG. 2C  is a diagram illustrating a masking film  204  applied over the photoresist layer  202  on the housing portion  200 . The masking film  204  includes opaque sections  206  and translucent sections  208 . The translucent sections  208  can provide a predetermined pattern for marking of the product housing. 
       FIG. 2D  is a diagram illustrating the housing portion  200  after having been exposed to radiation. For example, ultraviolet (UV) radiation can be directed at the photoresist layer  202  on the housing portion  200  through the masking film  204 . As a result, the exposed photoresist layer  202 ′ includes exposed photoresist regions  210  below the translucent sections  208  in the masking film  204 . 
       FIG. 2E  is a diagram illustrating the housing portion  200  having the remaining photoresist layer  202 ″. Here, the remaining photoresist layer  202 ″ results from removal of the masking film  204  and those regions  211  of the photoresist layer  202 ′ that were activated by the exposure to radiation. 
       FIG. 2F  is a diagram illustrating the housing portion  200  after a layer of material  212  is applied over the remaining photoresist layer  202 ″. The layer of material  212  is applied not only over the remaining portion of the photoresist layer  202 ″ but also directly over the outer surface of the housing portion  200  where the photoresist layer  202  has been removed. The layer of material  212  can, for example, be applied through a sputtering technique, such as through Physical Vapor Deposition (PVD). Also, as an example, the layer of material can be a metal. 
       FIG. 2G  is a diagram illustrating the housing portion  200  after the remaining photoresist layer  202 ″ is removed. Here, the layer of material  212  applied over the remaining portion of the photoresist layer  202 ″ is also removed. However, the portion of the layer of material  212 ′ that remains is that portion that has been provided directly over the outer surface of the housing portion  200 . 
       FIG. 2H  is a diagram illustrating the housing portion  200  after a protective coating  216  is applied on the outer surface of the housing portion  200  over the remaining portion of the layer of material  212 ′. 
       FIGS. 3A-3H  are diagrams detailing a product marking process according to another embodiment of the invention. The product marking process shown in  FIGS. 3A-3H  pertains to one embodiment of the product marking process  100  illustrated in  FIG. 1 . 
       FIG. 3A  is a diagram illustrating a housing portion  300 . The housing portion  300  can represent a portion of a product housing, such as an outer housing of an electronic device. In this embodiment, the housing portion  300  is curved. Marking is rendered more complicated when the surface to be marked has curvature. However, the product marking process according to the invention is suitable for use on flat, curved or complex surfaces. 
       FIG. 3B  is a diagram illustrating the housing portion  300  having a photoresist layer  302  applied thereon. 
       FIG. 3C  is a diagram illustrating a masking film  304  applied over the photoresist layer  302  on the housing portion  300 . The masking film  304  includes opaque sections  306  and translucent sections  308 . The translucent sections  308  can provide a predetermined pattern for marking of the product housing. 
       FIG. 3D  is a diagram illustrating the housing portion  300  after having been exposed to radiation. For example, ultraviolet (UV) radiation can be directed at the photoresist layer  302  on the housing portion  300  through the masking film  304 . As a result, the exposed photoresist layer  302 ′ includes exposed photoresist regions  310  below the translucent sections  308  in the masking film  304 . 
       FIG. 3E  is a diagram illustrating the housing portion  300  having the remaining photoresist layer  302 ″. Here, the remaining photoresist layer  302 ″ results from removal of the masking film  304  and those regions  311  of the photoresist layer  302 ′ that were activated by the exposure to radiation. 
       FIG. 3F  is a diagram illustrating the housing portion  300  after a layer of material  312  is applied over the remaining photoresist layer  302 ″. The layer of material  312  is applied not only over the remaining portion of the photoresist layer  302 ″ but also directly over the outer surface of the housing portion  300  where the photoresist layer  302  has been removed. The layer of material  312  can, for example, be applied through a sputtering technique, such as through Physical Vapor Deposition (PVD). Also, as an example, the layer of material can be a metal. 
       FIG. 3G  is a diagram illustrating the housing portion  300  after the remaining photoresist layer  302 ″ is removed. Here, the layer of material  312  applied over the remaining portion of the photoresist layer  302 ″ is also removed. However, the portion of the layer of material  312 ′ that remains is that portion that has been provided directly over the outer surface of the housing portion  300 . 
       FIG. 3H  is a diagram illustrating the housing portion  300  after a protective coating  316  is applied on the outer surface of the housing portion  300  over the remaining portion of the layer of material  312 ′. 
     In the product marking process  100  illustrated in  FIG. 1 , a photolithographic mask is used, where a photoresist layer is adhered to an outer surface housing. However, in other embodiment, a mask that performs a similar function can be formed from different techniques. As one example, a mask can be pad printed on the outer surface housing. As another example, a mask can be silk screened onto the outer surface housing. As still another example, a mask can be printed, such as with an ink jet printing device, onto the outer surface housing. 
     Another aspect described herein provides product marking using ablation. Here, material that is to be used for marking is deposited onto a product surface and then selectively ablated to yield the text and/or graphics for the product marketing. 
       FIG. 4  is a process flow diagram for a product marking process  400  according to another embodiment of the invention. In this embodiment, the product marking process  400  can mark a housing of an electrical device. For example, the product marking process  400  can be used to form text and/or graphics onto a housing surface, such as an outer housing surface, of an electrical device. 
     The product marking process  410  initially forms  402  a physical mask layer having at least one predetermined opening. The predetermined opening is, for example, an opening that surrounds a region were text or graphics is to be applied to the outer housing surface. In other words, the predetermined opening is oversized as compared to the region where text or graphic is to be applied on the outer housing surface. The physical mask layer can be implemented by a film having at die cut for the predetermined opening. In the event that the physical mask layer has more than one predetermined opening, the physical mask layer can have a die cut for each of the predetermined openings. 
     After the physical mask has been formed  402 , the physical mask layer can be adhered  404  to the outer housing surface. In one implementation, the physical mask layer can be adhered  404  to the outer housing surface through use of an adhesive. For example, the physical mask can have an adhesive backing. 
     Next, a layer of material can be deposited  406  onto the outer housing surface. For example, a deposition technique, such as sputtering, can be used to deposit  406  a layer of material onto the outer housing surface. In one implementation, the deposition technique uses a Physical Vapor Deposition (PVD) process. The layer of material being deposited  406  is the material that is to form the marking. For example, the layer of material can be a layer of metal, such as aluminum. Thereafter, the physical mask layer can be removed  408  from the outer housing surface. 
     After the physical mask layer has been removed  408 , the product marking process  400  can ablate  410  away portions of the layer of material that are not desired. The ablation  410  can utilize a laser to precisely remove portions of the layer of material that has been deposited  406  onto the outer housing surface. The ablation  410  can thus form specific graphical elements and/or text elements into the layer of material by ablation  410  of those portions of the layer of material that are not needed to represent the desired graphical elements and/or textual elements that are to remain on the outer housing surface. In one implementation, the laser performing the ablation  410  is a YV04 laser (e.g., 1064 nanometer (NM)). Through proper control of the laser, the ablation  410  of undesired portion of the layer of material can be removed without damaging the surface of the outer surface housing. 
     Subsequently, a translucent protective layer can be applied  412  to the outer housing surface. Although the translucent protective layer is not required, the translucent protective layer can serve to protect the remaining portion of the layer of material that is used to represent the one or more desired graphical elements and/or textual elements on the outer housing surface. For example, the translucent protective layer can be a layer of acrylic. Following the block  412 , the product marking process  400  can end. 
     It should be noted that the use of a physical mask in the product marking process  400  is optional. The physical mask serves to confine the area(s) where ablation is to be performed. Hence, in one embodiment, the product marking can be performed with simply operations  406  and  410  of the product marking process  400 , though this entails additional ablation. 
       FIGS. 5A-5E  are diagrams detailing a product marking process according to one embodiment of the invention. The product marking process shown in  FIGS. 5A-5D  pertains to one embodiment of the product marking process  400  illustrated in  FIG. 4 . 
       FIG. 5A  is a diagram illustrating a housing portion  500 . The housing portion  500  can represent a portion of a product housing, such as an outer housing of an electronic device. A mask layer  502  is attached to the housing portion  500 . The mask layer has at least one predetermined opening  503  that defines a region where marking of the outer housing is to be performed. 
       FIG. 5B  is a diagram illustrating the housing portion  500  having the mask layer  502  as well as a layer of material  504 . The layer of material  504  is applied over the predetermined opening  503  in the mask layer  502  and may also be applied over some or all of the mask layer  502 . 
       FIG. 5C  is a diagram illustrating the housing portion  500  having a remaining portion of the layer of material  504  that results after the mask layer  502  is removed from the housing portion  500 . The remaining portion of the layer of material  504  corresponds to the predetermined pattern. 
       FIG. 5D  is a diagram illustrating the housing portion  500  after the remaining portion of the layer of material  504  is abated to remove unwanted areas. As shown in  FIG. 5D , after the ablation, the layer of material  504  is now converted to specific marking elements  504 ′. The specific marking elements  504 ′ can pertain to text and/or graphic elements that are formed from the layer of material  504  using laser ablation. 
       FIG. 5E  is a diagram illustrating the housing portion  500  after a protective coating  506  is applied on the outer surface of the housing portion  500  over the specific marking elements  504 ′ that have been formed in the layer of material  504 . 
       FIGS. 6A and 6B  are diagrams illustrating exemplary marking of a product in accordance with a product marking process, such as the product marking process shown in  FIGS. 5A-5E  or the product marking process  400  illustrated in  FIG. 4 . 
       FIG. 6A  illustrates a product housing  600  according to one embodiment. The product housing  600  being illustrated can represent one surface, such as back surface, of a handheld electronic device. A predetermined region  602  of the illustrated surface can be coated or covered with a layer of material to be used for marking. As noted above, a masking layer can be used to confine the layer of material to the predetermined region  602 . 
       FIG. 6B  illustrates the product housing  600  after the layer of material in the predetermined region  602  has been ablated away to yield the desired labeling. In this example, the labeling includes a logo graphic  604 , serial number  606 , model number  608 , and certification/approval marks  610  and  612 . 
     In one embodiment, the product marking techniques discussed herein can be used to provide markings on a portable electronic device. The portable electronic device can further be a hand-held electronic device. The term hand-held generally means that the electronic device has a form factor that is small enough to be comfortably held in one hand. A hand-held electronic device may be directed at one-handed operation or two-handed operation. In one-handed operation, a single hand is used to both support the device as well as to perform operations with the user interface during use. In two-handed operation, one hand is used to support the device while the other hand performs operations with a user interface during use or alternatively both hands support the device as well as perform operations during use. In some cases, the hand-held electronic device is sized for placement into a pocket of the user. By being pocket-sized, the user does not have to directly carry the device and therefore the device can be taken almost anywhere the user travels (e.g., the user is not limited by carrying a large, bulky and often heavy device). 
     Additional information on product marking as well as other manufacturing techniques and systems for electronic devices are contained in U.S. Provisional Patent Application No. 61/059,789, filed Jun. 8, 2008, and entitled “Methods and Systems for Manufacturing an Electronic Device,” which is hereby incorporated herein by reference. 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     Different aspects, embodiments or implementations may, but need not, yield one or more of the following advantages. One advantage is that high precision markings can be provided to product housings. As an example, the marking being provided can have a resolution whereby thirty (30) micron line widths can be achieved. Another advantage is that the marking techniques are effective for surfaces that are flat or curved. Another advantage is that the marking techniques have good adhesion characteristics to product housings, such as plastic housings. Still another advantage is that markings can be formed that are metallic and reflective for superior visual appearance. Yet still another advantage is that one or several markings can be provided to one or more distinct areas of a product&#39;s housing. The various markings can be efficiently provided in a sequential or concurrent manner. 
     The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Metadata:
Filing Date: 20130122
Publication Date: 20151110
Grant Date: 20151110
Priority Date: 20080608
Inventors: HELEY RICHARD WALTER
LUO ERMING
MITTLEMAN ADAM
PAYNE JOHN
TAN TANG YEW
WANG ERIK
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K13/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T428/2462", "inventive": false, "first": false, "tree": "[]"}, {"code": "G03F7/2014", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03F7/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03F7/2016", "inventive": false, "first": false, "tree": "[]"}, {"code": "G03F7/202", "inventive": false, "first": false, "tree": "[]"}, {"code": "G03F7/2014", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K13/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "G03F7/202", "inventive": false, "first": false, "tree": "[]"}, {"code": "G03F7/2016", "inventive": false, "first": false, "tree": "[]"}, {"code": "G03F7/2014", "inventive": true, "first": false, "tree": "[]"}, {"code": "B41M5/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/2462", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T428/2462", "inventive": false, "first": false, "tree": "[]"}, {"code": "B41M5/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "G03F7/202", "inventive": false, "first": false, "tree": "[]"}, {"code": "G03F7/2016", "inventive": false, "first": false, "tree": "[]"}, {"code": "G03F7/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03F7/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K13/00", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 41785629