PATENT DOCUMENT

Publication Number: US-9882302-B2
Application Number: US-201615282750-A
Country: US
Kind Code: B2

Title: Enclosures having a seamless appearance

Abstract:
An enclosure for an AC to DC adapter has a continuous and apparently seamless exterior surface. The enclosure includes a housing and a cap that are joined by a pair of weld joints. One weld is formed on an interior portion of the enclosure providing strength and one weld joint is formed on the exterior surface providing a seamless appearance for the enclosure.

Claims:
What is claimed is: 
     
       1. An enclosure for an electronic assembly, the enclosure having a seamless exterior appearance and comprising:
 a housing comprising a bottom wall and at least one side wall extending from the bottom wall, the at least one side wall comprising a beveled end portion having a curved tip; 
 a cap comprising a protrusion coupled to the beveled end portion of the housing, wherein the cap, the bottom wall, and the at least one side wall define a cavity in which the electronic assembly is disposed; 
 a first weld joint formed between the protrusion and the beveled end portion of the housing and a second weld joint formed between the housing and the cap, wherein the first and the second weld joints are separated by a non-interference region; and 
 at least two electrical prongs extending through the bottom wall and electrically coupled to the electronic assembly. 
 
     
     
       2. The enclosure of  claim 1 , wherein the cap is coupled to the at least one side wall with a first and a second weld joint. 
     
     
       3. The enclosure of  claim 1  wherein the housing has a generally rectangular cross-section and the at least one side wall comprises four sidewalls. 
     
     
       4. The enclosure of  claim 1  wherein the housing has a round cross-section and the at least one side wall consists of a single sidewall. 
     
     
       5. The enclosure of  claim 2 , wherein the first and the second weld joints are separated by a distance and have a non-interference region between them. 
     
     
       6. The enclosure of  claim 5 , wherein the beveled end portion and the protrusion define the non-interference region with a pair of sloped surfaces. 
     
     
       7. The enclosure of  claim 6 , wherein the pair of sloped surfaces are both at an angle between 30 and 40 degrees. 
     
     
       8. The enclosure of  claim 2 , wherein the first weld joint is formed between the protrusion and the beveled end portion. 
     
     
       9. The enclosure of  claim 2  wherein the second weld joint is formed within an interference region disposed between the side wall and the cap. 
     
     
       10. The enclosure of  claim 2 , wherein the first and the second weld joints are ultrasonically formed welds. 
     
     
       11. The enclosure of  claim 1 , wherein at least a portion of a top surface of the cap is proud with respect to the curved tip of the beveled end portion. 
     
     
       12. The enclosure of  claim 1 , wherein a top surface of the cap is formed with a matte surface. 
     
     
       13. A method of forming an enclosure having a seamless exterior appearance for an electronic assembly, the method comprising:
 forming a housing having a bottom wall and at least one side wall extending from the bottom wall, the at least one side wall comprising a beveled end portion having a curved tip, and the bottom wall being formed around at least two electrical prongs extending through the bottom wall; 
 disposing the electronic assembly within the housing such that the electrical assembly is electrically coupled to the at least two electrical prongs; 
 positioning a cap comprising a protrusion on the housing; and 
 coupling the protrusion to the beveled end portion with a first joint and a second joint that are separated from each other by a non-interference region, wherein the cap, the bottom wall, and the at least one side wall define a cavity in which the electronic assembly is disposed. 
 
     
     
       14. The method of  claim 13 , wherein the protrusion is coupled to the beveled end portion with a first and a second joint. 
     
     
       15. The method of  claim 14  wherein the first and the second joints are formed by ultrasonic welding. 
     
     
       16. The method of  claim 15  wherein the second joint is formed by shear forces acting on an interference region disposed between the side wall and the cap. 
     
     
       17. The method of  claim 15  wherein the second joint is formed by compression forces acting on an interference region disposed between the side wall and the cap. 
     
     
       18. The method of  claim 14  wherein the first joint is formed by ultrasonic welding and the second joint is formed with an adhesive. 
     
     
       19. The method of  claim 14 , wherein the first and the second joints are separated by a distance and have a non-interference region between them. 
     
     
       20. The method of  claim 19 , wherein the beveled end portion and the protrusion define the non-interference region with a pair of sloped surfaces. 
     
     
       21. The method of  claim 20 , wherein the pair of sloped surfaces are both at an angle between 30 and 40 degrees. 
     
     
       22. The method of  claim 13 , wherein at least a portion of a top surface of the cap is proud with respect to the curved tip of the beveled end portion.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application 62/235,430 filed on Sep. 30, 2015, entitled “Corner-Angled Reveal for Electronic Enclosure”, which is incorporated by reference in its entirety and for all purposes. 
    
    
     FIELD 
     The described embodiments relate generally to enclosures that have the appearance of being seamless. More particularly, the present embodiments relate to plastic enclosures that appear seamless and house one or more electronics assemblies. 
     BACKGROUND 
     Currently there are a wide variety of electronic devices that have enclosures to facilitate the use of the electronic device and provide an aesthetic appearance. However, often such enclosures have one or more seams where plastic components of the enclosure meet. The seams can disrupt the exterior surface of the enclosure impairing its aesthetics and sometimes creating a relatively weak region of the enclosure that is prone to damage and breakage. This can be particularly problematic for enclosures that contain high-voltage electronic components that would be exposed if such a seam were to be broken. New enclosures are needed for electronic assemblies that are seamless, or at least have the appearance of being seamless, and/or that have improved structural integrity. 
     SUMMARY 
     Some embodiments of the present disclosure relate to enclosures having a seamless look and feel that are used to encase an electronic assembly. Some embodiments relate to an enclosure that can be used for any electronic device while other embodiments relate to an enclosure for an AC to DC adapter. 
     In some embodiments an enclosure for an electronic assembly has a seamless exterior appearance and comprises a housing including a bottom wall and at least one side wall extending from the bottom wall. The at least one side wall comprises a beveled end portion having a curved tip. A cap comprising a protrusion is coupled to the beveled end portion of the housing, wherein the cap, the bottom wall, and the at least one side wall define a cavity in which the electronic assembly is disposed. At least two electrical prongs are disposed through the bottom wall and are electrically coupled to the electronic assembly. 
     In some embodiments the cap is coupled to the at least one side wall with a first and a second weld joint. In various embodiments the first and the second weld joints are separated by a distance and have a non-interference region between them. In some embodiments the beveled end portion and the protrusion define the non-interference region with a pair of sloped surfaces. 
     In some embodiments the pair of sloped surfaces are both at an angle between 30 and 40 degrees. In various embodiments the first weld joint is formed between the protrusion and the beveled end portion. In some embodiments the second weld joint is formed within an interference region disposed between the side wall and the cap. In various embodiments the first and the second weld joints are ultrasonically formed welds. 
     In some embodiments at least a portion of a top surface of the cap is proud with respect to the curved tip of the beveled end portion. In various embodiments a top surface of the cap is formed with a matte surface. 
     In some embodiments a method of forming an enclosure having a seamless exterior appearance for an electronic assembly is disclosed , the method comprises forming a housing having a bottom wall and at least one side wall extending from the bottom wall. The at least one side wall comprises a beveled end portion having a curved tip, and the bottom wall is formed around at least two electrical prongs extending through the bottom wall. An electronic assembly is disposed within the housing such that the electrical assembly is electrically coupled to the at least two electrical prongs. A cap comprising a protrusion is positioned on the housing, and the protrusion is coupled to the beveled end portion. The cap, the bottom wall, and the at least one side wall define a cavity in which the electronic assembly is disposed. 
     In some embodiments the protrusion is coupled to the beveled end portion with a first and a second joint. In various embodiments the first and the second joints are formed by ultrasonic welding. In some embodiments the second joint is formed by shear forces acting on an interference region disposed between the side wall and the cap. In various embodiments the second joint is formed by compression forces acting on an interference region disposed between the side wall and the cap. 
     In some embodiments the first joint is formed by ultrasonic welding and the second joint is formed with an adhesive. In various embodiments the first and the second joints are separated by a distance and have a non-interference region between them. In some embodiments the beveled end portion and the protrusion define the non-interference region with a pair of sloped surfaces. In various embodiments the pair of sloped surfaces are both at an angle between 30 and 40 degrees. In some embodiments at least a portion of a top surface of the cap is proud with respect to the curved tip of the beveled end portion. 
     To better understand the nature and advantages of the present disclosure, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present disclosure. Also, as a general rule, and unless it is evident to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of an electronic device having a visually continuous exterior surface according to an embodiment of the disclosure; 
         FIG. 2A  is a front perspective view of an AC to DC adapter having a visually continuous exterior surface according to an embodiment of the disclosure; 
         FIG. 2B  is a cross-sectional view of a housing for the AC to DC adapter illustrated in  FIG. 2A ; 
         FIG. 2C  is a cross-sectional view of a housing including an electronic assembly for the AC to DC adapter illustrated in  FIG. 2A ; 
         FIG. 3  is a cross-sectional view of an interface between the housing and the cap portions of the enclosure illustrated in  FIG. 2A ; 
         FIG. 4  is a cross-sectional view of an interface between the housing and the cap portions of the enclosure illustrated in  FIG. 2A ; 
         FIG. 5  is a cross-sectional view of an interface between the housing and the cap portions of the enclosure illustrated in  FIG. 2A ; 
         FIG. 6  is a cross-sectional view of an interface between the housing and the cap portions of the enclosure illustrated in  FIG. 2A ; 
         FIG. 7  is a cross-sectional view of an injection molding apparatus for forming a housing according to an embodiment of the disclosure; 
         FIG. 8  is a close-up view of a portion of the injection molding apparatus illustrated in  FIG. 7 ; and 
         FIG. 9  is a method of forming an AC to DC adapter having an enclosure according to an embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Some embodiments of the present disclosure relate to electronic devices that have a plastic enclosure that has the appearance and feel of not including any seams (e.g., having an apparently seamless enclosure). Various embodiments relate to enclosures that can also have improved structural integrity at the enclosure edges and/or resiliency to water or dust penetration. While the present disclosure can be useful for a wide variety of configurations, some embodiments of the disclosure are particularly useful for high voltage electronic assemblies encased in plastic enclosures, as described in more detail below. 
     For example, in some embodiments an injection molded plastic housing is formed having a cavity configured to receive an electronics assembly. A cap is secured to the housing over the cavity forming a visually continuous exterior surface at seams where the housing and cap meet. In one embodiment the housing encases and forms a liquid-tight enclosure for an underwater diving device. 
     In another example an injection molded plastic housing is formed with a cavity and a pair of AC wall adapter prongs that extend out of a face of the housing. An AC to DC converter assembly that includes high voltage circuitry is installed within the cavity and coupled to the prongs. A cap is installed over the cavity, forming a visually continuous exterior surface at the seams where the cap meets the housing. The cap has an aperture through which a DC connector can be coupled to the AC to DC converter. 
     In order to better appreciate the features and aspects of housings having a seamless appearance according to the present disclosure, further context for the disclosure is provided in the following section by discussing two particular implementations of electronic devices according to embodiments of the present disclosure. These embodiments are for example only and other embodiments can be employed in other electronic devices such as, but not limited to computers, watches, media players, RFID tags and other devices. 
       FIG. 1  illustrates a simplified perspective view of an electronic device  100  according to some embodiments of the disclosure. As shown in  FIG. 1 , electronic device  100  has an enclosure  105  with a visually continuous exterior surface  110  having the appearance and feel of being seamless. More specifically, enclosure  105  includes a housing  115  and a cap  120  that are visually continuous at a seam  125  where the housing and cap meet. The seamless appearance can be aesthetically pleasing, and can also provide resilience to dust and liquid penetration. Further, seam  125  can be imperceptible to a user&#39;s touch giving electronic device  100  a smooth monolithic feel. In some embodiments seam  125  can be formed to have sufficient mechanical strength so that cap  120  cannot be easily separated from housing  115  and edges  130  of enclosure  105  resist fracturing. 
     In the embodiment shown in  FIG. 1 , enclosure  105  is illustrated as including a display  135  (e.g, a touch display) and first and second input buttons  140 ,  145 . Embodiments of the disclosure are not limited to any particular electronic device, however, and in other embodiments enclosure  105  can be used for devices that have different components than what is shown in  FIG. 1 . The seamless appearance of enclosure  105  can be both aesthetically pleasing and useful to make enclosure  105  liquid-tight. Since enclosure  105  has an undisrupted exterior surface, in some embodiments the electronic assembly within the enclosure can be inductively charged with an external and separate inductive charging station. In further embodiments enclosure  105  can have a battery or other power source within it. 
     In various embodiments enclosure  105  can be used to enclose other electronics assemblies such as, but not limited to a wireless communication transceiver, a wireless router, an RFID device, a wirelessly activated tag for locating lost keys or an AC to DC adapter, as explained in more detail below. In some particular embodiments enclosure  105  can be part of a device that includes wireless transceiver, a rechargeable battery and a wireless charging interface to charge the battery and not include any external connectors reducing possible paths of ingress for water or other moisture. In further embodiments, enclosure  105  can be used for purposes other than enclosing an electronic device. In one example, enclosure  105  can be used to enclose an antique (e.g., a coin or a piece of ancient artwork) that needs to protected from damage and have an aesthetically appealing appearance. 
     As defined herein, liquid-tight shall mean a seal that conforms to one or more of the following ratings as defined by the International Protection Rating and International Electrochemical Commission (IEC) 60529 that can also be known as the I.P. 68 rating. In some embodiments the liquid-tight seal will protect the electronic assembly against the harmful ingress of water and have a “liquid ingress” rating between 1 (dripping water) and 8 (immersion beyond 1 meter). In various embodiments the liquid-tight seal shall be rated between 1 (dripping water) and 4 (splashing water) while in some embodiments the liquid-tight seal shall be rated between 2 (dripping water with device tilted at 15 degrees) and 5 (water jet). In various embodiments the liquid-tight seal shall be rated between 3 (spraying water) and 6 (powerful water jets) while in some embodiments the liquid-tight seal shall be rated between 4 (splashing water) and 7 (immersion up to 1 meter). In various embodiments the liquid-tight seal shall be rated between 5 (water jets) and 8 (immersion beyond 1 meter) while in some embodiments liquid-tight shall mean the seal will protect the electronic device against liquid ingress up to 100 feet for 30 minutes. 
     Now referring to  FIG. 2A  a simplified perspective view of an electronic device  200  having a seamless appearance is illustrated. As shown in  FIG. 2A , electronic device  200  can be an AC to DC adapter that includes an enclosure  205  having a cap  210  secured to a housing  215  forming a visually continuous exterior surface  220 . In this embodiment, enclosure  205  encases an AC to DC electronics assembly (not shown in  FIG. 2A ), as discussed in more detail below. 
     Electronic device  200  has a pair of electrical prongs  230   a ,  230   b  that are configured to be plugged into an AC wall outlet to receive AC power. A receiving opening  235  is configured to receive a connector that can couple DC energy to a separate electronic device. In some embodiments continuous exterior surface  220  can provide device  200  with a pleasing feel for a user since housing  215  is not distinguishable from cap  210  by touch. In further embodiments seams  240  formed between cap  210  and housing  215 , can be configured to provide improved structural integrity such that enclosure  205  is able to withstand high mechanical forces. 
       FIGS. 2A-2B  illustrate sequential steps of forming electronic device  200 .  FIG. 2B  illustrates a cross-sectional view of housing  215 . Housing  215  can have a bottom wall  225  and at least one side wall  245  extending between bottom wall  225  and an opening  250 , forming a cavity  255 . In the example illustrated in  FIG. 2A , there can be four sidewalls or, alternatively, housing  215  can be cylindrically shaped such that side wall  245  has a round cross section. Bottom wall  225  can be formed around at least two electrical prongs  230   a ,  230   b  that are disposed through bottom wall  225  (the second prong is disposed directly behind the prong illustrated in  FIG. 2A ). More specifically, in some embodiments two electrical prongs  230   a ,  230   b  can be insert molded within housing  215 . In other embodiments at least two electrical prongs  230   a ,  230   b  can be inserted after the formation of housing  215 . Bottom wall  225  and side wall  245  can be formed of plastic, such as a polycarbonate, and can be fabricated with an injection molding machine. In one embodiment the polycarbonate material can be unfilled, while in other embodiments it can have between 1 percent and 20 percent glass fiber or other reinforcement. 
     Now referring to  FIG. 2C , an electronic assembly  260  including AC to DC power conversion circuitry has been inserted within cavity  255  and electrically coupled to at least two electrical prongs  230   a ,  230   b . A connector  265  can extend out of electronic assembly  260  and be used to supply DC power to a separate electronic device. In some embodiments, connector  265  can be a USB or other type of electrical connector, such as, but not limited to a USB Type-A connector, a USB micro connector or a USB Type-C connector. As further shown in  FIG. 2B , cap  210  can be installed onto housing  215 . Cap  210  can be formed of the same material as housing  215  using an injection molding machine. For example, cap  210  can be formed of plastic, such as a filled or unfilled polycarbonate. Cap  210  can include an opening  235  (see  FIG. 2A ) aligned with connector  265 . Opening  235  can be dimensioned to allow a connector to be inserted through the opening such that it can be coupled to connector  265 . 
     Cap  210  can be coupled to housing  215  using any suitable process. In some embodiments, an ultrasonic welding process can be used. Ultrasonic welding involves applying high-frequency (e.g., 20,000 Hz) ultrasonic acoustic vibrations to work pieces being held together under pressure to create a solid-state weld. To install cap  210  onto housing  215  as shown in  FIG. 2B , cap  210  can be positioned on housing  215  followed by an application of force (i.e. towards bottom wall  225 ) in combination with the ultrasonic vibrations. The vibrations cause heat to be generated at the interfaces where cap  210  and housing  215  are in contact with each other as a result of the applied force. The heat causes localized regions of cap  210  and housing  215  to melt and form weld joints  270   a ,  270   b  (or “interferences”) as discussed in more detail below. 
     In order for enclosure  205  to have the appearance of being continuous and seamless, weld joint  270   a  can be formed to be substantially imperceptible. Weld joints  270   a ,  270   b  should also be strong to prevent fracture or other mechanical failure resulting in cap  210  being decoupled from housing  215 . The desired strength and continuous appearance of enclosure  205  can be accomplished by molding cap  210  and housing  215  in particular geometries. Exemplary geometries are shown in  FIGS. 3-6  which illustrate expanded views of the regions of cap  210  and housing  215  at weld joints  270   a ,  270   b.    
       FIG. 3  illustrates a close-up cross-sectional view of one embodiment of cap  210  and housing  215  at weld joints  270   a ,  270   b . As shown in  FIG. 3 , weld joints  270   a  and  270   b  are separated by a distance  305  and have a non-interference region  310  between them formed by a pair of sloped surfaces. More specifically,  FIG. 3  illustrates weld joints  270   a ,  270   b  after ultrasonic welding has taken place. Dashed lines in regions of weld joints  270   a ,  270   b  illustrate pre-weld interference areas that have been melted and deformed to form the weld joints. 
     Sidewall  245  of housing  215  can include a beveled end portion  315  having a curved tip  320 . The cross-section of beveled end portion  315  shown in  FIG. 3  can be characterized by any suitable angle. In some embodiments, beveled end portion  315  can form an angle between 30° and 40° and in one embodiment about 35°. Curved tip  320  can also have any suitable radius of curvature. In some embodiments curved tip  320  can have a radius of curvature of 0.08 millimeters. 
     As further shown in  FIG. 3 , cap  210  can include a protrusion  325 . Protrusion  325  can have any suitable configuration. For example, in  FIG. 3 , protrusion  325  can extend to a point  330  such that the cross-section of protrusion  325  is characterized by an angle. In some embodiments, protrusion  325  can form an angle of about 35°. In some embodiments, point  330  can have a radius of curvature of about 0.04 millimeters. 
     Before ultrasonic welding, cap  210  can extend above sidewall  245  by 0.5 to 1.5 millimeters. However, after ultrasonic welding, cap  210  can extend above sidewall  245  by a protrusion distance  335 . In some embodiments protrusion distance  335  is between 10 microns and 200 microns while in various embodiments it can be between 50 microns and 150 microns and in some embodiments between 50 microns and 100 microns. The radius of curvature of curved tip  320 , protrusion  325  and the dimension of protrusion distance  335  can make joint  270   a  imperceptible both visually and to touch. For example, as a user runs their finger across top surface  340  of cap  210  and along sidewall  245  the user may not feel any discontinuities and cap and sidewall can feel as if they are a monolithic structure. In further embodiments, top surface  340  of cap  210  can be manufactured with a matte finish to further obscure joint  270   a  from visual or touch recognition. The matte finish can also be used to obscure a marred surface appearance that can be caused by the ultrasonic welding process. 
     Joint  270   a  can be formed from an interference between side wall  245  and cap  210  in a region that is between 0.25 and 0.35 millimeters wide and between 0.6 and 0.9 millimeters tall. Shear forces are placed on the interference region during ultrasonic bonding. A gap between side wall  245  and cap  210  that is about 0.05 millimeters can be formed annularly around the cap and immediately adjacent to weld  270   b.    
     When coupling protrusion  325  to beveled end portion  315  using ultrasonic welding, cap  210  can be attached such that it is proud (e.g., extends above) with respect to curved tip  320 . Such a configuration can account for deflection that can occur when force is applied to top surface  340  of cap  210 . As force is applied to cap  210  during ultrasonic welding, protrusion  325  can be configured to deflect into non-interference region  310  rather than beveled end portion  315  of housing  215  deflecting. The configuration shown in  FIG. 3  can result in protrusion  325  deflecting up towards curved tip  320 . As shown in  FIG. 3 , after ultrasonic welding no gap is present between point  330  of cap  210  and curved tip  320  of housing  215 , thereby creating a seamless appearance. 
     The deflection of protrusion  325  can result in top surface  340  of cap  210  being curved. For example, as protrusion  325  deflects upwards during ultrasonic welding, the central region of cap  210  may not deflect, creating a concave top surface. However, the radius of curvature of curved tip  320  can make such a curvature of cap  210  imperceptible both visually and to touch. For example, as a user runs their finger across the top surface of cap  210  and curved tip  320 , the combined surfaces can feel continuous (e.g., seamless or monolithic). Further, to avoid deformation of protrusion  325  and curved tip  320  at weld joint  270   a , the force and/or vibrations can be modified during ultrasonic welding. For example, vibrations can be applied as cap  210  is pushed downward towards housing  215  but only until point  330  contacts curved tip  320 . When the contact is made, the vibrations can be turned off but the downward force maintained. If the plastic at point  330  and curved tip  320  is sufficiently melted, weld joint  270   a  can be formed without further vibrations and without deforming the visible portions of protrusion  325  and curved tip  320 . 
     Using the process described above, weld joint  270   b  can be used primarily for structural and/or sealing purposes and weld joint  270   a  can be designed primarily for obscuring the weld joint so entire enclosure  205  appears seamless. Non-interference region  310  can be used to separate weld joint  270   a  from weld joint  270   b  so the ultrasonic energy is concentrated only on the two weld joints and weld joint  270   a  can be well-controlled such that it forms a seamless exterior appearance for enclosure  205 . 
       FIG. 4  illustrates a close-up cross-sectional view of another embodiment of cap  210  and housing  215  at weld joints  270   a ,  270   b  in accordance with various embodiments of the invention. As shown in  FIG. 4 , weld joints  270   a  and  270   b  are similar to those illustrated in  FIG. 4  and are separated by a distance  405  with a non-interference region  410  between them. Dashed lines in regions of weld joints  270   a ,  270   b  illustrate pre-weld interference areas that have been melted and deformed to form the weld joints. 
     Sidewall  245  of housing  215  can include a beveled end portion  415  having a curved tip  420 . The cross-section of beveled end portion  415  shown in  FIG. 3  can be characterized by any suitable angle. In some embodiments, beveled end portion  415  can form an angle of about 35°. Curved tip  420  can also have any suitable radius of curvature. In some embodiments curved tip  420  can have a radius of curvature of 0.08 millimeters. 
     As further shown in  FIG. 4 , cap  210  can include a protrusion  425 . Protrusion  425  can have any suitable configuration. For example, in  FIG. 4 , protrusion  425  can extend to a point  430  such that the cross-section of protrusion  425  is characterized by an angle. In some embodiments, protrusion  425  can form an angle of about 35°. In some embodiments, point  430  can have a radius of curvature of about 0.04 millimeters. 
     Before ultrasonic welding, cap  210  can extend above sidewall  245  between 1 to 2 millimeters. However, after ultrasonic welding, cap  210  can extend above sidewall  245  by a protrusion distance  435 . In some embodiments protrusion distance  435  is between 10 microns and 200 microns while in various embodiments it can be between 20 microns and 50 microns and in some embodiments between 20 microns and 40 microns. The radius of curvature of curved tip  420 , protrusion  425  and the dimension of protrusion distance  435  can make joint  270   a  imperceptible both visually and to touch. In further embodiments, top surface  440  of cap  210  can be manufactured with a matte finish to further obscure joint  270   a  from visual or touch recognition. 
     Joint  270   b  can be formed from an interference between side wall  245  and cap  210  in a region that is between 0.1 and 0.3 millimeters wide and between 1 and 2 millimeters tall. Shear forces are placed on the interference region during ultrasonic bonding. A gap between side wall  245  and cap  210  that is about 0.05 millimeters can be formed annularly around the cap and immediately adjacent to weld  270   b.    
     As discussed above, weld joint  270   b  can be used primarily for structural and/or sealing purposes and weld joint  270   a  can be designed primarily for obscuring the weld joint so entire enclosure  205  appears seamless. Non-interference region  410  can be used to separate weld joint  270   a  from weld joint  270   b  so the ultrasonic energy is concentrated only on the two weld joints and weld joint  270   a  can be well-controlled such that it forms a seamless exterior appearance for enclosure  205 . 
       FIG. 5  illustrates a close-up cross-sectional view of another embodiment of cap  210  and housing  215  at weld joints  270   a ,  270   b  in accordance with various embodiments of the invention. As shown in  FIG. 5 , weld joints  270   a  and  270   b  are separated by a distance  405  with a non-interference region  410  between them and weld joint  270   b  is formed by compression bonding rather than shear bonding that was illustrated in  FIGS. 3 and 4 . Dashed lines in regions of weld joints  270   a ,  270   b  illustrate pre-weld interference areas that have been melted and deformed to form the weld joints. 
     Sidewall  245  of housing  215  can include a beveled end portion  515  having a curved tip  520 . The cross-section of beveled end portion  515  shown in  FIG. 5  can be characterized by any suitable angle. In some embodiments, beveled end portion  515  can form an angle of about 40°. Curved tip  520  can also have any suitable radius of curvature. In some embodiments curved tip  520  can have a radius of curvature of 0.08 millimeters. 
     As further shown in  FIG. 5 , cap  210  can include a protrusion  525 . Protrusion  525  can have any suitable configuration. For example, in FIG. 5 , protrusion  525  can extend to a point  530  such that the cross-section of protrusion  525  is characterized by an angle. In some embodiments, protrusion  525  can form an angle of about 35°. In some embodiments, point  530  can have a radius of curvature of about 0.03 millimeters. 
     Before ultrasonic welding, cap  210  can extend above sidewall  245  between 0.5 to 1 millimeters. However, after ultrasonic welding, cap  210  can extend above sidewall  245  by a protrusion distance  535 . In some embodiments protrusion distance  435  is between 5 microns and 200 microns while in various embodiments it can be between 5 microns and 20 microns and in some embodiments about 10 microns. The radius of curvature of curved tip  520 , protrusion  525  and the dimension of protrusion distance  535  can make joint  270   a  imperceptible both visually and to touch. In further embodiments, top surface  540  of cap  210  can be manufactured with a matte finish to further obscure joint  270   a  from visual or touch recognition. 
     Joint  270   b  can be formed from an interference between side wall  245  and cap  210  in a region that extends up from the side wall between 1 to 2 millimeters and is between 0.2 and 0.5 millimeters wide. In one embodiment the interference has a radius of about 0.32 millimeters. Compression forces are placed on the interference region during ultrasonic bonding. A gap between side wall  245  and cap  210  that is about 0.05 millimeters can be formed annularly around the cap and immediately adjacent to weld  270   b.    
     As discussed above, weld joint  270   b  can be used primarily for structural and/or sealing purposes and weld joint  270   a  can be designed primarily for obscuring the weld joint so entire enclosure  205  appears seamless. Non-interference region  510  can be used to separate weld joint  270   a  from weld joint  270   b  so the ultrasonic energy is concentrated only on the two weld joints and weld joint  270   a  can be well-controlled such that it forms a seamless exterior appearance for enclosure  205 . 
       FIG. 6  illustrates a close-up cross-sectional view of another embodiment of cap  210  and housing  215  at weld joints  270   a ,  270   b  in accordance with various embodiments of the invention.  FIG. 6  illustrates a “tongue and groove” configuration where side wall  245  of housing  215  includes a groove  605  and the bottom surface of cap  210  includes a tongue  610 . Although weld joint  270   a  is formed using ultrasonic welding, weld joint  270   b  can be formed by either ultrasonic welding or with an adhesive. In some embodiments weld joint  270   b  is formed by applying an adhesive (e.g., an epoxy) to the groove of housing  215  and/or the tongue of cap  210 . A downward force applied during ultrasonic bonding of weld joint  270   a  causes the tongue to be inserted into the groove which are then bonded upon drying (or curing) of the adhesive. 
     As discussed above, weld joint  270   b  can be used primarily for structural and/or sealing purposes and weld joint  270   a  can be designed primarily for obscuring the weld joint so entire enclosure  205  appears seamless. In some embodiments a non-interference region can be used to separate weld joint  270   a  from weld joint  270   b , however in other embodiments a non-interference region may not be used. 
       FIGS. 7-8  illustrate cross-sections of an injection molding apparatus  700  in accordance with various embodiments of the invention. As shown in  FIG. 7 , an injection mold tool  705  can be used to form a housing  710  that can be similar to housing  215  illustrated in  FIG. 5 . During formation of housing  710 , injection mold tool  705  can form undesirable “parting lines” on housing  710  that can result in a disruptive exterior surface. However, as described herein, injection molding tool  705  can be configured to form the parting lines on regions of housing  710  that allow the completed enclosure to maintain a seamless appearance, as described in more detail below. 
     More specifically, in some embodiments injection mold tool  705  can involve the use of a cavity  715 , a core  720 , a core insert  723  and one or more metal slides  725  that meet at tooling interfaces  730  that can leave “parting lines”  735 ,  736  remaining on housing  710 . In one example, cavity  715 , a core  720  and one or more metal slides  725  are arranged so parting line  735  is formed on housing  710  just below curved tip  745  in a region that is covered by a cap (such as cap  210  illustrated in more detail in  FIG. 5 ). In another example, parting line  736  is formed away from weld joint  270   a  (see  FIG. 5 ) and below curved tip  745 . More specifically, parting line  736  can be moved a sufficient distance away from curved tip  745 , such that parting line  736  does not look or feel like a seam in the completed enclosure and the enclosure maintains a seamless appearance and feel. 
       FIG. 9  illustrates a method of forming an AC to DC adapter having a seamless enclosure. In step  905  a housing is formed. In some embodiments the housing has a bottom wall and at least one side wall extending from the bottom wall. The at least one side wall includes a beveled end portion having a curved tip. The bottom wall is formed around at least two electrical prongs extending through the bottom wall. 
     In step  910  an electronics assembly is placed within the housing. The electronics assembly is electrically coupled to the at least two electrical prongs. In step  915  a cap is positioned on the housing such that it encases the electronics assembly. The cap has a protrusion disposed around a peripheral edge. In step  920  the protrusion of the cap is coupled to the beveled end portion of the housing such that the cap, the bottom wall, and the at least one side wall define a cavity in which the electronic assembly is disposed. In some embodiments the cap is ultrasonically welded to the housing. 
     Although electronic devices  100  and  200  (see  FIGS. 1 and 2 , respectively) are described and illustrated as two particular electronic devices, embodiments of the disclosure are suitable for use with a multiplicity of electronic devices. For example, any device that encloses an electrical assembly can be used with embodiments of the invention 
     In some instances, embodiments of the disclosure are particularly well suited for use with portable electronic devices because of the importance of their aesthetic appearance. As used herein, an electronic media device includes any device with at least one electronic component. Such devices can include, for example, portable music players (e.g., MP3 devices and Apple&#39;s iPod devices), portable video players (e.g., portable DVD players), cellular telephones (e.g., smart telephones such as Apple&#39;s iPhone devices), wireless routers, video cameras, digital still cameras, projection systems (e.g., holographic projection systems), gaming systems, PDAs, as well as tablet (e.g., Apple&#39;s iPad devices), laptop or other mobile computers. Some of these devices can be configured to provide audio, video or other data or sensory output. 
     For simplicity, various internal components, such as the AC to DC power conversion circuitry, bus, memory, storage device and other components of electronic devices  100  and  200  (see  FIGS. 1 and 2A , respectively) are not shown in the figures. 
     In the foregoing specification, embodiments of the disclosure have been described with reference to numerous specific details that can vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the disclosure, and what is intended by the applicants to be the scope of the disclosure, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction. The specific details of particular embodiments can be combined in any suitable manner without departing from the spirit and scope of embodiments of the disclosure. 
     Additionally, spatially relative terms, such as “bottom or “top” and the like can be used to describe an element and/or feature&#39;s relationship to another element(s) and/or feature(s) as, for example, illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use and/or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as a “bottom” surface can then be oriented “above” other elements or features. The device can be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Metadata:
Filing Date: 20160930
Publication Date: 20180130
Grant Date: 20180130
Priority Date: 20150930
Inventors: KWAN ALEXANDER M.
VILLARREAL CESAR LOZANO
RAMOS SIRI AMRIT
ZHANG XUYANG
Dvorak Peter A.
Assignee: APPLE INC
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Family ID: 57206355