PATENT DOCUMENT

Publication Number: US-8220142-B2
Application Number: US-24043608-A
Country: US
Kind Code: B2

Title: Method of forming a housing component

Abstract:
Electronic devices are provided with housing components that have improved aesthetics. One or more holes may be formed through a portion of the housing and then the housing portion may be anodized. The anodization process may increase or decrease the geometries of each hole. The holes may be formed through the housing portion from a cosmetic side of the housing portion to an interior side of the housing portion.

Claims:
1. A method of forming a housing component for an electronic device, the method comprising:
 providing a piece of material for creating a portion of the housing component; 
 forming at least one hole through the piece of material; and then 
 anodizing the piece of material, wherein the piece of material provides a cosmetic side and an internal side of the housing component, and wherein the forming comprises forming the at least one hole initially from the cosmetic side, through the piece of material, to the internal side. 
 
     
     
       2. The method of  claim 1 , wherein the anodizing increases the size of the at least one hole. 
     
     
       3. The method of  claim 1 , wherein the anodizing decreases the size of the at least one hole. 
     
     
       4. The method of  claim 1 , wherein a cross-sectional area of the at least one hole is reduced after the anodizing the piece of material. 
     
     
       5. The method of  claim 1 , wherein the method further comprises forming a cavity into the internal side where the at least one hole is formed. 
     
     
       6. The method of  claim 1 , wherein the at least one hole has a first opening comprising a first cross-sectional area and a second opening comprising a second cross-sectional area, and wherein the first cross-sectional area is different from the second cross-sectional area. 
     
     
       7. The method of  claim 1 , wherein the shape of the housing component is one of hexahedral, spherical, ellipsoidal, conoidal, and octahedral. 
     
     
       8. The method of  claim 1 , wherein the anodizing the piece of material comprises:
 degreasing the piece of material; 
 rinsing the piece of material; 
 etching the piece of material; 
 polishing the piece of material; 
 dyeing the piece of material; 
 sealing the piece of material; and 
 drying the piece of material. 
 
     
     
       9. The method of  claim 1 , wherein the forming the at least one hole comprises at least one of laser drilling, laser cutting, laser machining, laser ablating, electron beam machining, electro-discharge machining, chemical milling, metal injection molding, and conventional drilling. 
     
     
       10. The method of  claim 1 , wherein the piece of material is a sheet of metal. 
     
     
       11. The method of  claim 1 , wherein the at least one hole comprises:
 a first opening formed through the cosmetic side of the housing component; 
 a second opening formed through the internal side of the housing component; and 
 a hollow passageway extending between the first opening and the second opening, wherein:
 the first opening comprises a first cross-sectional area; 
 the second opening comprises a second cross-sectional area; and 
 the first cross-sectional area is larger than the second cross-sectional area. 
 
 
     
     
       12. A method of forming a housing component for an electronic device, the method comprising:
 providing a piece of material, wherein the piece of material comprises an inner surface for creating an internal surface of a portion of the housing component, and wherein the piece of material comprises an outer surface for creating a cosmetic surface of the portion of the housing component; 
 forming at least one hole through the piece of material between the inner surface and the outer surface, wherein the forming comprises forming the at least one hole initially from the outer surface, through the piece of material, to the inner surface; and 
 anodizing the piece of material, wherein the anodizing changes the size of the at least one hole. 
 
     
     
       13. The method of  claim 12  further comprising positioning an input/output interface component adjacent the inner surface, wherein the at least one hole provides at least one passageway for information to be communicated between the interface component and an environment adjacent the outer surface. 
     
     
       14. The method of  claim 12 , wherein the anodizing increases the size of the at least one hole. 
     
     
       15. The method of  claim 12 , wherein the anodizing decreases the size of the at least one hole. 
     
     
       16. The method of  claim 12  further comprising forming a cavity into the inner surface at the location where the at least one hole is formed. 
     
     
       17. The method of  claim 12 , wherein the at least one hole has a first opening comprising a first cross-sectional area and a second opening comprising a second cross-sectional area, and wherein the first cross-sectional area is different from the second cross-sectional area. 
     
     
       18. The method of  claim 12 , wherein the anodizing the piece of material comprises:
 degreasing the piece of material; 
 rinsing the piece of material; 
 etching the piece of material; 
 polishing the piece of material; 
 dyeing the piece of material; 
 sealing the piece of material; and 
 drying the piece of material. 
 
     
     
       19. The method of  claim 12 , wherein the forming the at least one hole comprises at least one of laser drilling, laser cutting, laser machining, laser ablating, electron beam machining, electro-discharge machining, chemical milling, metal injection molding, and conventional drilling. 
     
     
       20. The method of  claim 12 , wherein the at least one hole comprises:
 a first opening formed through the outer surface; 
 a second opening formed through the inner surface; and 
 a hollow passageway extending between the first opening and the second opening, wherein:
 the first opening comprises a first cross-sectional area; 
 the second opening comprises a second cross-sectional area; and 
 the first cross-sectional area is larger than the second cross-sectional area.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This claims the benefit of U.S. Provisional Application No. 60/997,656, filed Oct. 3, 2007, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This relates to methods and apparatus for providing holes through housing components of electronic devices. 
     BACKGROUND OF THE DISCLOSURE 
     Some known electronic devices (e.g., computers and telephones) include at least one internal electronic component associated with the operation of the device and a protective housing that at least partially encloses the one or more internal electronic components. Typically, the housing includes one or more housing components that serve to surround the internal electronic components at a peripheral region of the electronic device so as to cover and protect the internal components from adverse conditions. Also, one or more holes may be provided through one or more of the housing components. Information transmitted from and/or received by the internal electronic components may be passed through the one or more holes provided through the housing component of the electronic device. 
     Cosmetic features are important to consumers of electronic devices, as these features help create the overall impression that one has of the electronic device. Therefore, the housing and the holes provided through the housing may also be configured to form and aesthetically enhance the outward appearance of the electronic device. For example, the shape, contours, and/or color of the housing and/or the holes provided through the housing may be designed so as to create a positive impression about the electronic device, thereby contributing to the overall success of the device in the market place. 
     Accordingly, what is needed are apparatus and methods for providing holes through housing components of various electronic devices. 
     SUMMARY OF THE DISCLOSURE 
     Apparatus and methods for providing holes through housing components of various electronic devices are provided. 
     According to one embodiment of the invention, there is provided a method of forming a housing component for an electronic device. The method may include providing a piece of material for creating a portion of the housing component, forming at least one hole through the piece of material, and then anodizing the piece of material. 
     According to another embodiment of the invention, there is provided a method of forming a housing component for an electronic device. The method may include providing a piece of material with an inner surface and an outer surface for creating a portion of the housing component, forming at least one hole through the piece of material between the inner surface and the outer surface, and anodizing the piece of material, wherein the anodizing changes the size of the at least one hole. 
     According to another embodiment of the invention, there is provided an electronic device that includes a housing component. The housing component may include an anodized piece of material with an inner surface, an outer surface, and at least one hole through the anodized piece of material between the inner surface and the outer surface. An anodization layer may cover at least a portion of the piece of material within the at least one hole. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects of the invention, its nature, and various advantages will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1  is a top, front, right perspective view of an electronic device in accordance with some embodiments of the invention; 
         FIG. 2  is a top elevational view of a portion of the electronic device of  FIG. 1 ; 
         FIG. 3  is a cross-sectional view of a portion of the electronic device of  FIGS. 1 and 2 , taken from line III-III of  FIG. 2 ; 
         FIG. 3A  is a cross-sectional view, similar to  FIG. 3 , of a portion of an electronic device in accordance with other embodiments of the invention; 
         FIG. 3B  is a cross-sectional view, similar to  FIGS. 3 and 3A , of a portion of an electronic device in accordance with yet other embodiments of the invention; 
         FIG. 3C  is a cross-sectional view, similar to  FIGS. 3-3B , of a portion of an electronic device in accordance with yet still other embodiments of the invention; 
         FIG. 4  is a cross-sectional view of a portion of the electronic device of  FIGS. 1-3 , similar to  FIG. 3 , but with an additional component in accordance with some embodiments of the invention; 
         FIG. 5A  is a cross-sectional view of a portion of an electronic device, similar to  FIGS. 3 and 4 , after a first step in a creation process in accordance with some embodiments of the invention; 
         FIG. 5B  is a cross-sectional view of the portion of the electronic device of  FIG. 5A  after a second step in the creation process in accordance with some embodiments of the invention; and 
         FIG. 6  is a flowchart of an anodization process in accordance with some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Apparatus and methods are provided for providing holes through housing components of various electronic devices. The invention will now be described with reference to  FIGS. 1-6 . 
       FIGS. 1-4  show an embodiment of an electronic device  100  including at least one housing component constructed in accordance with the invention. The term “electronic device” can include, but is not limited to, music players, video players, still image players, game players, other media players, music recorders, video recorders, cameras, other media recorders, radios, medical equipment, domestic appliances, transportation vehicle instruments, calculators, cellular telephones, other wireless communication devices, personal digital assistants, programmable remote controls, pagers, laptop computers, desktop computers, printers, and combinations thereof. In some cases, the electronic device may perform a single function (e.g., a device dedicated to playing music) and, in other cases, the electronic device may perform multiple functions (e.g., a device that plays music, displays video, stores pictures, and receives and transmits telephone calls). 
     Moreover, in some cases, the electronic device may be any portable, mobile, hand-held, or miniature electronic device having at least one housing component constructed in accordance with the invention so as to allow a user to use the device wherever the user travels. A miniature electronic device may have a form factor that is smaller than that of hand-held electronic devices, such as an iPod™ available by Apple Inc. of Cupertino, Calif. An illustrative miniature electronic device can be integrated into various objects that include, but are not limited to, watches, rings, necklaces, belts, accessories for belts, headsets, accessories for shoes, virtual reality devices, other wearable electronics, accessories for sporting equipment, accessories for fitness equipment, key chains, and combinations thereof. Alternatively, an electronic device that includes at least one housing component of the invention may not be portable at all, but may instead be generally stationary, such as a television or a desktop computer (e.g., an iMac™ available by Apple Inc.). 
     Electronic device  100  can include at least one electronic component (e.g., a processor, memory region, display component, transmitter, receiver, etc.) and a protective housing (e.g., housing  101 ) that at least partially encloses the one or more electronic components of the device. As shown in  FIG. 1 , for example, housing  101  of device  100  may at least partially enclose a device output component  197  (e.g., a video display screen) and a user input component  199  (e.g., a scroll wheel). Moreover, as shown in  FIG. 1 , housing  101  can be hexahedral. Although, it should be noted that housing  101  of device  100  is only exemplary and need not be substantially hexahedral, and that, in some embodiments, the housing of device  100  can generally be formed in any other suitable shape, including, but not limited to, substantially spherical, ellipsoidal, conoidal, octahedral, or a combination thereof, for example. 
     In some embodiments, housing  101  may include at least one housing component formed from metal. The metal housing component may be configured to make the electronic device look as if the electronic device was formed from a single block of metal (i.e., a solid piece of metal that has been hollowed out). 
     In other embodiments, however, housing  101  may not be formed from a block of material, as the cost of doing this can be quite expensive. That is, although the housing component may look as though it was machined to give it its net shape from a single block of material, it may in fact be formed by other processes designed to mimic the machined look. 
     In some embodiments, a metal housing component that looks like it was formed from a block of material may be formed rather from a piece of sheet of metal (e.g., flat stock). That is, the sheet metal may be formed in such a way that the final part looks like it was machined down from a large thick slab of material. By utilizing sheet metal, the overall cost of the part can be reduced (e.g., it is very expensive to machine down a large piece of metal as it wastes a lot of material and time). 
     In some embodiments, the shape of the housing component may be at least partially created by drawing and, more particularly, by deep drawing portions of the sheet of metal. Additionally or alternatively, the shape of the housing component may be at least partially created by forging portions of the sheet of metal. Additionally or alternatively, the shape of the housing component may be at least partially created by machining portions of the sheet of metal. For example, a sheet of metal may be deep drawn to form a housing component with a front wall and side walls extending therefrom (e.g., to form a box or can with one open end). The housing component may be configured with a front wall and top, right side, left side, and bottom walls at the peripheral edge portions of the front wall. The front wall as well as the other walls may include various openings for devices associated with the electronic device. For example, the front wall may include an opening for a display of the electronic device (e.g., device output component  197 ). Thereafter, portions of the housing component may be forged to affect its geometry at specific locations (e.g., to change the shape and/or thickness of the material at specific locations). Thereafter, portions of the housing component may be machined to form a near net shape. 
     One or more small holes may be provided at least partially through at least a portion of at least one housing component according to the invention. For example, in some embodiments, such holes may provide passageways for information to be communicated through the housing to and/or from one or more electronic components of the device (e.g., an input/output (“I/O”) interface component). The I/O component may be positioned adjacent the inner surface of the housing component under one or more of the small holes, thereby creating an I/O interface. 
     Any portion of any housing component may include one or more holes formed therethrough for providing an I/O (“input/output”) interface, such as that described in Andre et al., U.S. Published Patent Application No. 2008/0084404, published Apr. 10, 2008, and Andre et al., U.S. Published Patent Application No. 2008/0024470, published Jan. 31, 2008, each of which is hereby incorporated by reference herein in its entirety. 
     For example, as shown in  FIGS. 1-4 , one or more holes  150  may be provided through a portion  103  of a housing component (e.g., a top wall) of housing  101 . It is to be understood that housing component portion  103  may be any portion of any housing component of any electronic device in accordance with the invention. 
     Each hole  150  may be provided between a “cosmetic” or outer surface  102  and an opposite or “internal” or inner surface  104  of portion  103  of housing  101 . Two or more holes  150  may form a collection or pattern  158  of neighboring holes  150  on outer surface  102  of portion  103 . Each hole  150  may be defined by an outer opening  152  in outer surface  102 , an inner opening  154  in inner surface  104 , and a hollow passageway  156  extending therebetween. 
     Portion  103  of housing  101  may be made of any suitable material that may retain the structural integrity of the housing component, including, for example, metal (e.g., 6063 aluminum) and plastic. Portion  103  of the housing component may be provided with an overall thickness T (see, e.g.,  FIG. 3 ). In some embodiments, thickness T may be in the range of 0.5 millimeters to 5.5 millimeters. In some embodiments, thickness T may be in the range of 1.5 millimeters to 4.5 millimeters. In some embodiments, thickness T may be in the range of 2.5 millimeters to 3.5 millimeters. In some embodiments, thickness T may be about 3.0 millimeters. In other embodiments, thickness T may be in the range of 0.25 millimeters to 0.75 millimeters. In some embodiments, thickness T may be in the range of 0.35 millimeters to 0.65 millimeters. In some embodiments, thickness T may be in the range of 0.45 millimeters to 0.55 millimeters. In some embodiments, thickness T may be about 0.49 millimeters. 
     However, in some embodiments, a cavity  110  may be formed into inner surface  104  of portion  103  at the location where inner openings  154  of holes  150  are to be provided. Cavity  110  may be formed by any suitable process, such as laser ablating, for example. As shown in  FIG. 3 , for example, cavity  110  may reduce the thickness of portion  103  of housing  101  to a reduced thickness t at the location where inner openings  154  of holes  150  are to be provided. In some embodiments, reduced thickness t may be in the range of 0.2 millimeters to 0.8 millimeters. In some embodiments, reduced thickness t may be in the range of 0.3 millimeters to 0.7 millimeters. In some embodiments, reduced thickness t may be in the range of 0.4 millimeters to 0.6 millimeters. In some embodiments, reduced thickness t may be about 0.5 millimeters. In other embodiments, reduced thickness t may be in the range of 0.05 millimeters to 0.45 millimeters. In some embodiments, reduced thickness t may be in the range of 0.15 millimeters to 0.35 millimeters. In some embodiments, reduced thickness t may be about 0.25 millimeters. 
     The formation of cavity  110  may facilitate the formation of holes  150  by reducing the thickness of portion  103  from thickness T to reduced thickness t at the location where inner openings  154  of holes  150  are to be provided, and thereby reducing the amount of material of portion  103  to be excavated during the process of creating holes  150 . However, it is to be understood that, in certain embodiments, the formation of cavity  110  may not appreciably improve the overall efficiency or speed of manufacturing holes  150  through portion  103 . For example, when thickness T of portion  103  is not particularly thick, the additional time and effort required to manufacture holes  150  may be less than the additional time and effort required to first form cavity  110 . In such a case, it may be more efficient and economical to omit the cost and delay associated with forming cavity  110  before creating holes  150 . 
     An input/output (“I/O”) interface component may be provided adjacent the inner surface of the housing component under one or more holes provided therein for creating an I/O interface. As shown in  FIG. 4 , for example, an I/O component  170  may be provided adjacent inner surface  104  of portion  103 . In one embodiment, I/O component  170  may be positioned such that an outer surface  172  of I/O component  170  faces an inner opening  154  of one or more holes  150  in portion  103 . If portion  103  includes a cavity  110 , cavity  110  may be sized such that I/O component  170  fits therein. 
     I/O component  170  may be any component suitable for transmitting and/or receiving information through one or more holes  150  proximal thereto. A minimum aspect ratio of the total cross-sectional area of the openings of holes  150  formed through portion  103  with respect to the total cross-sectional area or surface area of the active portion of I/O component  170  may be carefully designed to meet the performance specifications of that particular I/O component. 
     For example, in one embodiment, I/O component  170  may be a microphone that is capable of receiving sound waves transmitted from a source external to the housing component (e.g., external source  180 ) through one or more holes  150 . The minimum aspect ratio of the combined total cross-sectional area of outer openings  152  and/or of inner openings  154  of holes  150  with respect to the total surface area of the active portion of microphone I/O component  170  (e.g., the total surface area of the transducer or sensor used to receive sound waves) may be chosen to meet specific performance requirements of microphone  170 . In some embodiments, this minimum aspect ratio may be in the range of 10% to 30%. In some embodiments, this minimum aspect ratio may be in the range of 15% to 25%. In some embodiments, this minimum aspect ratio may be about 18.4%. 
     As shown in  FIG. 4 , for example, microphone I/O component  170  may include an active portion  175  that spans all of outer surface  172 . Moreover, as shown in  FIG. 4 , active portion  175  and outer surface  172  of I/O component  170  may also span all of inner surface  104  of portion  103  defined by cavity  110 . In this embodiment, in which holes  150  may be utilized to pass sound waves from external source  180  to I/O component  170  configured as a microphone, each hole  150  may be provided with a circular outer opening  152  having a diameter d (see, e.g.,  FIGS. 2-4 ), for example. Moreover, cavity  110  may be formed within portion  103  as a cylinder having a diameter D (see, e.g.,  FIGS. 2-4 ) and, therefore, active portion  175  of microphone  170  may also be cylindrical with a diameter D. 
     In this particular illustrative embodiment, seven equally shaped holes  150  are provided through portion  103  as a pattern  158 . Therefore, in order to meet specific performance specifications of microphone  170 , the combined cross-sectional area of all seven holes  150  in pattern  158  must be at least a specifically chosen percentage of the surface area of active portion  175  (i.e., have a specifically chosen aspect ratio). For example, in one embodiment, if diameter D of active portion  175  is 1.5 millimeters and if the minimum required aspect ratio of microphone  170  is 18.4%, each of the seven holes  150  of pattern  158  may be formed with an outer opening  152  having a diameter d equal to about 0.25 millimeters. 
     It is to be understood, that the foregoing is just illustrative, and that active I/O component active portion  175 , cavity  110 , pattern  158 , and each one of holes  150  and its openings  152  and  154  may be formed of any suitable size and shape, including, but not limited to, triangular, rectangular, elliptical, etc. Moreover, pattern  158  may be formed of any suitable number of holes  150 , including just one hole, for example. Each hole  150  in pattern  158  may be separated from other holes  150  in pattern  158  by any suitable distance, depending on the size of pattern  158  and the function of holes  150  with respect to an associated I/O component  170 . 
     For example, in another embodiment, I/O component  170  may include one or more light sources capable of transmitting light through one or more holes  150  towards a user or other entity external to the housing component (e.g., viewer  190  of  FIG. 3 ). Alternatively, I/O component  170  may include one or more receptors that may be sensitive to visible light received through one or more holes  150  from an entity external to the housing component for providing ambient light sensing (“ALS”), for example. I/O component  170  may include one or more receptors that may be sensitive to infra-red light (“IR”) received through one or more holes  150  from an entity external to the housing component for receiving IR control signals from a remote control transmitter, for example. I/O component  170  may also be configured as an antenna, a proximity detector, a motion detector, or any other suitable I/O device that may transmit and/or receive information via one or more holes  150 . 
     In some embodiments, one or more holes  150  may be formed by creating a hollow passageway in portion  103  between an outer opening in outer surface  102  and an inner opening in inner surface  104  such that substantially all sides of the passageway are parallel with one another. Moreover, the sides of the passageway may also be parallel with an axis that is substantially perpendicular to outer surface  102  and substantially in the center of pattern  158 . For example, as shown in  FIGS. 2 and 3 , the walls of each of hollow passageways  156  in portion  103  between an outer opening  152  in outer surface  102  and an inner opening  154  in inner surface  104  may be substantially parallel with an axis A that is substantially perpendicular to outer surface  102  and that may be substantially in the center of pattern  158 . 
     In other embodiments, one or more holes may be formed by creating a tapered hollow passageway in portion  103  between outer surface  102  and inner surface  104  such that one or more side portions of the passageway are angled with respect to each other. Moreover, one or more side portions of the passageway may be angled with respect to an axis that is substantially perpendicular to outer surface  102 . For example, as shown in  FIG. 3A , at least one of the walls of each of hollow passageways  156 A in portion  103  between an outer opening  152 A in outer surface  102 A and an inner opening  154 A in inner surface  104 A may be angled towards axis A (i.e., “angled inwardly”). As shown in  FIG. 3B , for example, at least one of the walls of each of hollow passageways  156 B in portion  103  between an outer opening  152 B in outer surface  102 B and an inner opening  154 B in inner surface  104 B may be angled away from axis A (i.e., “angled outwardly”). 
     As shown in  FIG. 3A , for example, each of holes  150 A may be tapered such that the aspect ratio of the cross-sectional area of outer opening  152 A to the cross-sectional area of inner opening  154 A is less than 1 (i.e., the size of outer opening  152 A is less than the size of inner opening  154 A). In some embodiments, this aspect ratio may be in the range of 1:6 to 1:2. In some embodiments, this aspect ratio is about 1:3. However, in other embodiments, as shown in  FIG. 3C , for example, each of holes  150 C may be tapered such that the aspect ratio of the cross-sectional area of outer opening  152 C to the cross-sectional area of inner opening  154 C is greater than 1 (i.e., the size of outer opening  152 C is greater than the size of inner opening  154 C). In some embodiments, this aspect ratio may be in the range of 6:1 to 2:1. In some embodiments, this aspect ratio is about 3:1. The angle and aspect ratio of each hole  150  may be varied according to its particular application for providing an I/O interface. 
     Although shown greatly enlarged in  FIGS. 2-4 , one or more of holes  150  may be imperceptible or invisible to the unaided human eye. That is, the cross-sectional area of outer opening  152  of one or more holes  150  may be too small to be resolvable by a user looking at outer surface  102  of portion  103 . The average limit of resolution for the unaided adult human eye is about 0.10 millimeters at a viewing distance of about 1 meter. For children, the average limit of resolution is somewhat finer (e.g., 0.04 millimeters at a viewing distance of about 1 meter). Therefore, depending on the anticipated viewer  190  and the anticipated viewing distance V between his or her eye  192  and outer surface  102  of portion  103 , the cross-sectional area of outer opening  152  of one or more holes  150  may be selected to be below the limit of resolution of user  190 , thereby being imperceptible or invisible to user&#39;s eye  192  (see, e.g.,  FIG. 3 ). 
     Thus, as defined herein, the term “invisible hole” may refer to any hole with an outer opening that is smaller than what may be resolvable by an unaided human eye at an anticipated viewing distance. Conversely, it is to be understood that the term “visible hole,” as defined herein, may refer to any hole with an outer opening that is large enough to be resolvable by an unaided human eye at an anticipated viewing distance. 
     Each hole  150  may be formed through portion  103  of housing  101  using one or more suitable techniques, including, but not limited to, laser drilling, laser cutting, laser machining, laser ablating, electron beam machining, electro-discharge machining (“EDM”), chemical milling, metal injection molding, conventional drilling, and combinations thereof. The one or more techniques used may depend on the size and shape of the desired hole  150  and the size and material of portion  103 , for example. In some embodiments, an ultra-violet (“UV”) computer numerical controlled (“CNC”) laser tool having a 1,000 picometer wavelength laser beam with a focal width (i.e., spot size) of about 0.015 millimeters may be used to form one or more holes  150  in portion  103 . In other embodiments, a green or yttrium-aluminium-garnet (“YAG”) laser may be used, for example, when forming holes with a larger cross-sectional area (e.g., holes with a diameter or cross-sectional length of 0.045 millimeters or greater). 
     A tapered hole (e.g., holes  150 A,  150 B, or  150 C) may be formed by a type of trepanning process, wherein the orbit of a laser may tighten or expand as the laser drills deeper into portion  103 , for example. A hole  150  may be formed by percussively excavating an entire passageway (e.g., passageway  156 ) through portion  103 . Alternatively, a hole  150  may be formed by excavating the section of portion  103  about the passageway, between the perimeters of the openings defining the hole (e.g., the section of portion  103  about passageway  156 , between the perimeters of openings  152  and  154 , in the shape of a hollow cylinder). Then, the remaining material of portion  103  that has been isolated by this excavation may be pushed out of the remainder of portion  103  (e.g., by a jet stream of air), thereby leaving a hole  150 . An additional drilling step may then be performed within passageway  156  (e.g., by trepanning) to smooth the inner surface of hole  150 . 
     The formation of holes  150  using the methods described above may tend to create burrs, roughness, and other indentations and deformations on the surface of the housing portion through which the excavation or removal of material begins. Therefore, holes  150  have conventionally been formed by initiating removal of the housing material from the “internal” or inner surface  104  of portion  103  that is opposite “cosmetic” or outer surface  102 . This may help to reduce the amount of burrs and rough edges created on the cosmetic side of the housing. However, it may be desirable to form holes  150  by initiating removal of the housing material from the “cosmetic” or outer surface  102  while minimizing the amount of burrs and rough edges on the cosmetic surface  102  created by such a formation process. 
     In accordance with some embodiments of the invention, one or more holes may be created through a portion of a housing component of an electronic device using one or more suitable techniques, including, but not limited to, laser drilling, laser cutting, laser machining, laser ablating, electron beam machining, electro-discharge machining (“EDM”), chemical milling, metal injection molding, conventional drilling, and combinations thereof, by initiating the creation of each hole from the cosmetic side of the housing portion. For example, as shown in  FIG. 5A , one or more holes  250  may be provided through a portion  203  of a housing of an electronic device according to some embodiments of the invention. Each hole  250  may be provided between a cosmetic or outer surface  202  and an opposite or inner surface  204  of portion  203 . Each hole  250  may be defined by an outer opening  252  in outer surface  202 , an inner opening  254  in inner surface  204 , and a hollow passageway  256  extending therebetween. The formation of holes  250  is shown in  FIG. 5A  in the early stages thereof, with two holes  250   a  and  250   b  formed, and laser drilling of a third hole  250   c  having just begun. 
     As shown, formation of holes  250  may be performed from outer surface  202  using a laser  282 . Laser  282  may have a laser beam  284  with a focal width  285 . For example, laser  282  may be an ultra-violet (“UV”) computer numerical controlled (“CNC”) laser tool having a 1,000 picometer wavelength laser beam  284  with a focal width  285  (i.e., spot size) of about 0.015 millimeters. 
     As shown in  FIG. 5A , for example, in order to achieve a “tapered” or gradual narrowing geometry for each hole  250 , laser beam  284  may be configured with a focal width  285  that is no larger, and preferably less, than the smallest diameter of the tapered hole that is to be formed. For example, if inner opening  254  of hole  250  through inner surface  204  is to be formed with an inner diameter id, focal width  285  may be no larger than id. In one embodiment, id may be 0.025 millimeters. Therefore, focal width  285  may be no larger than 0.025 millimeters. In other embodiments, focal width  285  may be no larger than half the size of the smallest diameter (e.g., no larger than 0.0125 millimeters). 
     Once focal width  285  is selected, laser beam  284  may be initially orbited around the edges of hole  250 , as illustrated with respect to hole  250   c , where the dotted lines embraced within the arrow indicate orbit  286  of laser beam  284 . The orbiting of laser beam  284  may be initiated by describing the initial opening in the housing portion (e.g., outer opening  252  in cosmetic outer surface  202 ). For example, if outer opening  252  of hole  250  through outer surface  202  is to be formed with an outer diameter od, orbit  286  may initially enter surface  202  with a diameter od. In some embodiments, od may be about 0.075 millimeters. Therefore, orbit  286  may initially enter surface  202  with a diameter of about 0.075 millimeters. As hole  250  forms and deepens (e.g., in the downward direction along axis A), orbit  286  of laser beam  284  may correspondingly tighten to progressively reduce the diameter of orbit  286 , and thus reduce the diameter of hole  250 . At the conclusion of the hole formation at inner surface  204 , in some embodiments, orbit  286  may have been progressively and continuously reduced until it is only about 0.050 millimeters, which may still be larger than focal width  285  of about 0.025 millimeters, for example. In other embodiments, the diameter of orbit  286  may be maintained as beam  284  forms and deepens hole  250 , such that substantially all sides of the passageway are parallel with one another (see, e.g., holes  150  of  FIG. 3 ). Alternatively, the diameter of orbit  286  may be increased as beam  284  forms and deepens hole  250 , such that one or more side portions of the passageway are angled away from axis A, such that diameter id of inner opening  254  may be greater than diameter od of outer opening  252  (not shown). 
     As mentioned, this process of forming holes may create burrs, rough edges, and various other types of indentations and deformations on the surface of the housing portion through which the excavation begins. For example, as shown in  FIG. 5A , deformations  205  may be formed on cosmetic or outer surface  202  of housing portion  203 . Conventionally, an electronic device housing, such as a housing made of aluminum, for example, may be anodized before forming holes therethrough. However, according to some embodiments of the invention, the material of housing portion  203  may be anodized after the formation of holes  250  for reducing or eliminating deformations  205 . 
     Anodization is an electrolytic process for aluminum and its alloys to produce a protective layer through electro-chemical oxidation. Among other things, anodization may serve the function of corrosion resistance, scratch and wear resistance, electrical insulation, cleanliness, and aesthetic enhancement. For example, as shown in  FIG. 6 , housing portion  203  may be anodized by one or more of the following steps in an anodization process  600 : a degreasing step  602 , a first rinsing step  604  (e.g., with water), a first etching step  606  (e.g., with Alkaline), a first chemical polishing step  608 , a second rinsing step  610 , a second etching step  612  (e.g., with Satin), a third rinsing step  614 , a second chemical polishing step  616 , a fourth rinsing step  618 , a dyeing step  620  (e.g., with a black dye), a fifth rinsing step  622 , a sealing step  624 , a sixth rinsing step  626 , and a drying step  628 . It is to be understood that process  600  of  FIG. 6  is purely illustrative, and various other anodization processes may be used in accordance with the invention. It is also to be understood that the steps shown in  FIG. 6  are merely illustrative and that steps may be modified, added, or omitted. 
     By anodizing a housing portion after holes have been formed therethrough, as opposed to anodizing before hole formation, the surfaces about the openings of the holes and the surfaces of the passageways may be cleaned and provided with an anodization layer. For example, as shown in  FIG. 5B , once portion  203  of the housing has been anodized, deformations  205  may be minimized or completely removed by the anodization process. Therefore, a drawback of forming the holes through the housing from the cosmetic side (e.g., deformations  205  on the cosmetic side) may be eliminated by anodizing the housing portion after the formation of the holes. Thus, housing portions whose geometries may have previously made laser drilling from the internal side impossible due to size constraints (e.g., a cylindrical housing that could not fit a laser machine therein for forming holes initially through the internal surface) may now have holes formed therethrough from the cosmetic side. 
     Moreover, by anodizing a housing portion after holes have been formed therethrough, as opposed to anodizing before hole formation, the walls of each hole passageway may be anodized like the inner and outer surfaces of the housing portion. For example, by anodizing portion  203  after holes  250  have been formed therethrough, the walls of passageways  256  may be anodized and may include an anodization layer, for example, like outer surface  202  and inner surface  204 . Therefore, the walls of passageways  256  may be of substantially the same color and appearance as the inner and/or outer surfaces, thereby further reducing the visibility of holes  250  to a user. 
     Anodization of housing portion  203  after the formation of holes  250  may also alter the size of outer openings  252  and inner openings  254 . For example, while some steps of the anodization process may increase the size of the openings and passageway of each hole (e.g., degreasing step  602 , etching steps  606  and  612 , etc.), other steps may decrease the size of the openings and passageway of each hole (e.g., polishing steps  608  and  616 , dyeing step  620 , etc.). By tweaking the characteristics of the various steps of the anodization process (e.g., process  600 ), the original geometry of each hole  250  created during formation may be varied during anodization. 
     For example, as shown in  FIG. 5B , the anodization process may change the size of the openings of hole  250  from inner diameter id to inner diameter id′ at inner opening  254  and from outer diameter od to outer diameter od′ at outer opening  252 . In some embodiments, if inner diameter id′ after anodization is larger than inner diameter id after formation, then the focal width  285  of laser beam  284  used to form hole  250  prior to anodization may be reduced. This ability to initially drill a smaller hole may help to reduce the cycle time of the machine (e.g., laser  282 ) forming the holes, thereby improving the number of parts per yield per machine on a given time frame. In other embodiments, if inner diameter id′ after anodization is smaller than inner diameter id after formation, then the focal width  285  of laser beam  284  used to form hole  250  prior to anodization may be increased. This ability to initially drill a larger hole may help to reduce the precision or complexity of the machine (e.g., laser  282 ) forming the holes. 
     While there have been described apparatus and methods for providing holes through housing components of various electronic devices, it is to be understood that many changes may be made therein without departing from the spirit and scope of the present invention. It is also to be understood that various directional and orientational terms such as “front” and “back” and “rear,” “left” and “right,” “top” and “bottom,” “side” and “edge” and “corner,” “height” and “width” and “depth,” “thickness” and “diameter,” and the like are used herein only for convenience, and that no fixed or absolute directional or orientational or geometrical limitations are intended by the use of these words. For example, the devices of this invention can have any desired orientation. If reoriented, different directional or orientational terms may need to be used in their description, but that will not alter their fundamental nature as within the scope and spirit of this invention. Those skilled in the art will appreciate that the invention can be practiced by other than the described embodiments, which are presented for purposes of illustration rather than of limitation, and the invention is limited only by the claims which follow.

Metadata:
Filing Date: 20080929
Publication Date: 20120717
Grant Date: 20120717
Priority Date: 20071003
Inventors: LIM WAY CHET
Assignee: APPLE INC
CPC Classifications: [{"code": "B23K26/384", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K26/364", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K15/085", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K26/384", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K26/389", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K15/085", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49117", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49117", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49165", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23K26/364", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K26/389", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49165", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 40523039