PATENT DOCUMENT

Publication Number: US-12074363-B2
Application Number: US-202318109168-A
Country: US
Kind Code: B2

Title: Coupling structures for electronic device housings

Abstract:
A housing for an electronic device is disclosed. The housing comprises a first component and a second component separated from the first component by a gap. The housing also includes a first molded element disposed at least partially within the gap and defining at least a portion of an interlock feature, and a second molded element disposed at least partially within the gap and mechanically engaging the interlock feature. The first component, the second component, and the second molded element form a portion of an exterior surface of the housing. A method of forming the housing is also disclosed.

Claims:
What is claimed is: 
     
       1. A tablet computer comprising:
 a front cover defining a front exterior surface of the tablet computer; and 
 a housing coupled to the front cover and comprising:
 a first metal housing component defining:
 a first portion of a back exterior surface of the housing; 
 a portion of a first side exterior surface of the housing; 
 a portion of a second side exterior surface of the housing; and 
 
 a second metal housing component defining a corner portion of the housing, the corner portion extending from the first side exterior surface of the housing to a third side exterior surface of the housing; and 
 a polymer joint structure positioned in a gap between the first metal housing component and the second metal housing component and defining a second portion of the back exterior surface of the housing. 
 
 
     
     
       2. The tablet computer of  claim 1 , wherein:
 the corner portion is a first corner portion; 
 the polymer joint structure is a first polymer joint structure; 
 the gap is a first gap; and 
 the housing further comprises:
 a third metal housing component defining a second corner portion of the housing; and 
 a second polymer joint structure in second gap between the first metal housing component and the third metal housing component and defining a third portion of the back exterior surface of the housing. 
 
 
     
     
       3. The tablet computer of  claim 2 , further comprising wireless communication circuitry positioned within the housing and electrically coupled to the second metal housing component, wherein the second metal housing component operates as an antenna for the wireless communication circuitry. 
     
     
       4. The tablet computer of  claim 3 , wherein:
 the antenna is a first antenna; 
 the wireless communication circuitry is coupled to the third metal housing component; and 
 the third metal housing component operates as a second antenna for the wireless communication circuitry. 
 
     
     
       5. The tablet computer of  claim 1 , wherein:
 the first metal housing component defines a first interlock feature; 
 the second metal housing component defines a second interlock feature; and 
 the polymer joint structure engages the first interlock feature and the second interlock feature. 
 
     
     
       6. The tablet computer of  claim 1 , wherein:
 the portion of the first side exterior surface of the housing is a first portion of the first side exterior surface of the housing; and 
 the polymer joint structure further defines a second portion of the first side exterior surface of the housing. 
 
     
     
       7. The tablet computer of  claim 6 , wherein the second metal housing component defines a third portion of the first side exterior surface of the housing. 
     
     
       8. An electronic device comprising:
 a transparent cover defining a front exterior surface of the electronic device; and 
 a housing coupled to the transparent cover and defining a back surface of the electronic device and a side surface of the electronic device, the side surface positioned between the transparent cover and the back surface of the electronic device, the housing comprising:
 a first metal housing component defining at least a portion of the back surface of the electronic device and a first portion of the side surface of the electronic device; 
 a second metal housing component defining a second portion of the side surface of the electronic device; 
 a third metal housing component defining a third portion of the side surface of the electronic device; 
 a first polymer material positioned within a first gap between the first metal housing component and the second metal housing component and defining a fourth portion of the side surface of the electronic device; and 
 a second polymer material positioned within a second gap between the first metal housing component and the third metal housing component and defining a fifth portion of the side surface of the electronic device. 
 
 
     
     
       9. The electronic device of  claim 8 , further comprising wireless communication circuitry within the housing and conductively coupled to at least one of the second metal housing component or the third metal housing component. 
     
     
       10. The electronic device of  claim 9 , wherein the at least one of the second metal housing component or the third metal housing component that is conductively coupled to the wireless communication circuitry operates as an antenna for the electronic device. 
     
     
       11. The electronic device of  claim 8 , wherein:
 the second metal housing component defines a first corner portion of the housing; and 
 the third metal housing component defines a second corner portion of the housing. 
 
     
     
       12. The electronic device of  claim 8 , wherein the first polymer material retains the first metal housing component to the second metal housing component. 
     
     
       13. The electronic device of  claim 8 , wherein:
 the side surface of the electronic device is a first side surface of the electronic device; and 
 the first metal housing component further defines a portion of a second side surface of the electronic device, the second side surface opposite the first side surface. 
 
     
     
       14. The electronic device of  claim 13 , wherein:
 the portion of the back surface of the electronic device is a first portion of the back surface of the electronic device; and 
 the first polymer material defines a second portion of the back surface of the electronic device; and 
 the second polymer material defines a third portion of the back surface of the electronic device. 
 
     
     
       15. A portable electronic device comprising:
 a housing comprising:
 a unitary metal housing component defining:
 at least a portion of a back surface of the housing; 
 at least a portion of a first side surface of the housing; and 
 at least a portion of a second side surface of the housing; 
 
 an antenna component defining a corner portion of the housing extending between the first side surface of the housing and a third side surface of the housing; and 
 a molded polymer structure positioned in a gap between the unitary metal housing component and the antenna component and configured to electrically isolate the antenna component from the unitary metal housing component; and 
 
 a front cover coupled to the housing and defining a front surface of the portable electronic device. 
 
     
     
       16. The portable electronic device of  claim 15 , wherein:
 the antenna component is first antenna component; 
 the corner portion is a first corner portion; and 
 the housing further comprises a second antenna component defining a second corner portion of the housing extending between the first side surface of the housing and a fourth side surface of the housing. 
 
     
     
       17. The portable electronic device of  claim 16 , wherein:
 the molded polymer structure is a first molded polymer structure; 
 the gap is a first gap; and 
 the housing further comprises a second molded polymer structure positioned in a second gap between the unitary metal housing component and the second antenna component and configured to electrically isolate the second antenna component from the unitary metal housing component. 
 
     
     
       18. The portable electronic device of  claim 15 , wherein:
 the portion of the back surface of the housing is a first portion of the back surface of the housing; and 
 the molded polymer structure comprises:
 a first segment defining a second portion of the back surface of the housing; and 
 a second segment defining a third portion of the back surface of the housing. 
 
 
     
     
       19. The portable electronic device of  claim 18 , wherein:
 the portion of the first side surface of the housing is a first portion of the first side surface of the housing; and 
 the molded polymer structure further comprises a third segment defining a second portion of the first side surface of the housing. 
 
     
     
       20. The portable electronic device of  claim 15 , wherein:
 the unitary metal housing component defines a first interlock feature; 
 the antenna component defines a second interlock feature; and 
 the molded polymer structure engages the first interlock feature and the second interlock feature.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application is a continuation patent application of U.S. patent application Ser. No. 17/555,920, filed Dec. 20, 2021 and titled “Coupling Structures for Electronic Device Housings,” which is a continuation patent application of U.S. patent application Ser. No. 16/740,753, filed Jan. 13, 2020 and titled “Coupling Structures for Electronic Device Housings,” now U.S. Pat. No. 11,223,105, which is a continuation patent application of U.S. patent application Ser. No. 16/147,703, filed Sep. 29, 2018 and titled “Coupling Structures for Electronic Device Housings,” now U.S. Pat. No. 10,559,872, which is a continuation patent application of U.S. patent application Ser. No. 15/233,891, filed Aug. 10, 2016 and titled “Coupling Structures for Electronic Device Housings,” now U.S. Pat. No. 10,148,000, which is a nonprovisional patent application of and claims the benefit of U.S. Provisional Patent Application No. 62/214,558, filed Sep. 4, 2015 and titled “Coupling Structures for Electronic Device Housings,” the disclosures of which are hereby incorporated herein by reference in their entireties. 
    
    
     FIELD 
     The subject matter of this disclosure relates generally to coupling structures for electronic device housings, and more particularly to coupling structures for joining housing components with molded polymer materials. 
     BACKGROUND 
     Electronic device housings often include multiple components that are coupled together to form the housing. For example, two or more housing portions may be coupled together to form an outer surface of the housing and to form an interior cavity in which components of the electronic device are housed. For different materials and more complex geometries, existing techniques for coupling housing portions may not be suitable for creating bonds of sufficient strength between components, and may not be capable of producing a surface finish and appearance necessary for exterior surfaces of an electronic device housing. 
     SUMMARY 
     Described herein are structures for coupling housing components of electronic device housings. For example, as described herein, a polymer material may be molded or otherwise disposed between two or more housing components to form a molded polymer element that couples the housing components together. The housing components may include various interlock features that mechanically engage with the molded element in order to form a secure coupling between the housing components and the molded element. The molded element may include portions made of different materials to benefit from the properties of each different material. For example, a first polymer material having a high strength may be used to form one portion of the molded element, while a second polymer material that is more easily polished or that forms a smoother outer surface may be used for a portion of the molded element that forms part of an exterior surface of the housing. 
     Some embodiments provide a housing for an electronic device. The housing includes a first component and a second component separated from the first component by a gap. The housing also includes a first molded element disposed at least partially within the gap and defining at least a portion of an interlock feature, and a second molded element disposed at least partially within the gap and mechanically engaging the interlock feature. The first component, the second component, and the second molded element form a portion of an exterior surface of the housing. 
     Some embodiments provide a housing for an electronic device. The housing includes a first component, a second component separated from the first component by a gap, and a joint structure disposed at least partially within the gap. The first component and the second component comprise flanges defining first and second portions, respectively, of a frame adapted to receive a transparent cover. A tooth of the joint structure extends past a ledge of the joint structure and forms a third portion of the frame. The joint structure includes a support structure that supports the tooth. 
     Some embodiments provide a housing for an electronic device. The housing includes a first housing portion forming a first portion of an exterior surface of the housing, and a second housing portion separated from the first housing portion by a gap and forming a second portion of an exterior surface of the housing. The housing further includes a molded element disposed in the gap and comprising a guide structure configured to bias at least a portion of the molded element toward an interior of the housing in response to a narrowing of the gap. 
     Some embodiments provide a method of forming a housing for an electronic device. The method includes forming a first molded element by flowing a material into a gap between a first housing component and a second housing component, flowing the material against a first interlock feature of the first housing component to couple the material to the first housing component, and flowing the material against a second interlock feature of the second housing component to couple the material to the second housing component. The method further includes forming a second molded element in the gap to form an exterior surface of the electronic device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG.  1    shows an example electronic device; 
         FIG.  2    shows a back of the example electronic device of  FIG.  1   ; 
         FIG.  3    shows an exploded view of an example electronic device housing; 
         FIG.  4    shows a portion of an example electronic device housing; 
         FIG.  5    shows a back of the electronic device housing of  FIG.  4   ; 
         FIG.  6    shows the electronic device housing of  FIG.  4   ; 
         FIG.  7    shows a partial cross-sectional view of the electronic device housing of  FIG.  4    taken along line  7 - 7  in  FIG.  4   ; 
         FIG.  8    shows a partial cross-sectional view of the electronic device housing of  FIG.  4    taken along line  8 - 8  in  FIG.  4   ; 
         FIG.  9    shows an expanded view of a portion of the electronic device housing shown in region  415  of  FIG.  4   ; 
         FIG.  10    shows a partial cross-sectional view of an embodiment of the electronic device housing of  FIG.  4    taken along line  10 - 10  in  FIG.  6   , showing an interlock feature that includes a protrusion; 
         FIG.  11    shows a partial cross-sectional view of the embodiment of the electronic device housing of  FIG.  10    taken along line  11 - 11  in  FIG.  10   ; 
         FIG.  12    shows a partial cross-sectional view of another embodiment of the electronic device housing of  FIG.  4    taken along line  10 - 10  in  FIG.  6   , showing an interlock feature that includes a protrusion with a through-hole; 
         FIG.  13    shows a partial cross-sectional view of the embodiment of the electronic device housing of  FIG.  12    taken along line  13 - 13  in  FIG.  12   ; 
         FIG.  14    shows a partial cross-sectional view of yet another embodiment of the electronic device housing of  FIG.  4    taken along line  10 - 10  in  FIG.  6   , showing an interlock feature that includes a recess; 
         FIG.  15    shows a partial cross-sectional view of yet another embodiment of the electronic device housing of  FIG.  4    taken along line  10 - 10  in  FIG.  6   , showing an interlock feature that includes a slot; 
         FIGS.  16 A- 16 C  show partial cross-sectional views of yet another embodiment of the electronic device housing of  FIG.  4    taken along line  10 - 10  in  FIG.  6   , showing an interlock feature that includes a tapered through-hole; 
         FIGS.  17 A- 17 C  show partial cross-sectional views of yet another embodiment of the electronic device housing of  FIG.  4    taken along line  10 - 10  in  FIG.  6   , showing an interlock feature that includes a threaded hole; 
         FIG.  17 D  shows a partial cross-sectional view of yet another embodiment of the electronic device housing of  FIG.  4    taken along line  10 - 10  in  FIG.  6   , showing multiple interlock features; 
         FIGS.  18 - 20 C  show partial exploded views of the electronic device housing of  FIG.  4   , showing various embodiments of a guide structure for a molded element; 
         FIG.  21 A  shows a partial exploded view of the electronic device housing of  FIG.  4   , showing a molded element that includes an example gusset; 
         FIG.  21 B  shows a partial view of the molded element of  FIG.  21 A ; 
         FIG.  22 A  shows a partial exploded view of the electronic device housing of  FIG.  4   , showing a molded element that includes another example gusset; 
         FIG.  22 B  shows a partial view of the molded element of  FIG.  22 A ; 
         FIG.  23 A  shows a partial view of the electronic device housing of  FIG.  4   , showing a molded element with a chamfer; 
         FIG.  23 B  shows a partial view of the molded element of  FIG.  23 A ; and 
         FIG.  24    is a flow chart of a method of forming a housing for an electronic device. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     Housings for electronic devices may be made up of multiple different components. For example, a housing may include a first component that forms a back surface of the housing, a second component that forms a side or edge of the housing, and so on. In order to join the first and second components (for example), a polymer material (or other suitable material) may be molded in or into a gap between the components. In order to produce a suitably strong coupling between the components, the first and second housing components include interlock features with which the polymer material engages. The polymer material may be molded into the gap in a viscous or flowable state such that it flows into, surrounds, and/or otherwise engages the interlock features of the housing components. Once the polymer material hardens, the engagement between the polymer material and the interlocks securely couples the housing portions together. An interlock (or interlock feature) is a structure or feature that engages another structure or feature to retain a component to one or more other components. Interlocks may include, for example, threads (e.g., threaded posts, holes, or other surfaces), undercuts, dovetails, grooves, protrusions, notches, channels, or the like. 
     The gaps between housing components may be configured such that the material within the gap forms part of the exterior surface. For example, joint structures may be disposed in gaps between housing components, and may be part of the exterior surface of the housing. In some cases, a material that is suitable for structurally joining housing components is not ideal for forming an exterior surface of the housing, and vice versa. As one non-limiting example, whereas strength and rigidity may be important properties for a joining material, surface finish and chemical resistance may be equally or more important for a material that will form part of an exterior surface of the housing. Accordingly, multiple materials may be molded into a gap, and each material may be selected to satisfy a particular design constraint or requirement. For example, a first material may be molded into the gap to structurally couple the housing components. A second material may then be molded into the gap, over the first material, to form part of an exterior surface of the housing. By using multiple materials in a gap, the materials can each be optimized for specific purposes and/or characteristics. 
     In the following figures and description, similar instances of particular components or features may be designated by additional indicators appended to the element number. For example, particular instances of first molded elements may be designated  400 - 1 ,  400 - 2 , etc. References to an element number without any additional indicator (e.g., the first molded elements  400 ) apply to any or all instances of that component or feature, and references to an element number with an additional indicator (e.g., the first molded element  400 - 1 ) apply to a particular instance of that component or feature. Moreover, any discussion related to an individual instance of a component or feature (e.g., the first molded element  400 - 1 ) may also apply to other instances of that component (e.g., the first molded element  400 - 2 ). 
       FIG.  1    shows an example electronic device  100  embodied as a smartphone. While the device  100  is a smartphone, the concepts presented herein may apply to any appropriate electronic, including wearable devices (e.g., watches), laptop computers, handheld gaming devices, tablet computers, computing peripherals (e.g., mice, touchpads, keyboards), or any other device. Accordingly, any reference to an “electronic device” encompasses any and all of the foregoing. 
     The electronic device includes a cover  102 , such as a glass, plastic, or other substantially transparent material, component, or assembly, attached to a housing  104 . As shown, the housing  104  can be a multi-piece housing. For example, the housing  104  can be formed from a body portion  200  and end portions  202 ,  204  ( FIG.  2   ). The device  100  also includes internal components, such as processors, memory, circuit boards, batteries, sensors, and the like. Such components, which are not shown, may be disposed within an interior volume defined at least partially by the housing  104 . 
       FIG.  2    shows a back view of the device  100 . The housing  104  includes a body portion  200  and end portions  202 ,  204  (also referred to herein as a top portion  202  and a bottom portion  204 ). The body portion  200  and the end portions  202 ,  204  may be formed from any appropriate material, such as aluminum, titanium, amorphous metals, polymer, or the like. 
     The housing  104  also includes a joint structure  206 - 1  between the body portion  200  and the top portion  202 , and a joint structure  206 - 2  between the body portion  200  and the bottom portion  204 . Joint structures are structures that couple and/or retain one component to another component. For example, the joint structures  206  couple the end portions  202 ,  204  to the body portion  200 , as described herein. The joint structures  206  may include multiple layers and/or portions, each of which may be formed from any appropriate material. For example, joint structures or portions thereof may be formed from polymers such as nylon, polyether ether ketone, polysulfone, polyphenylsulfone, polyaryletherketone, polyetherimide, polyethersulfone, or any other appropriate material. Moreover, the joint structures  206  may be reinforced with reinforcing fibers of glass, carbon, ceramics, or any other appropriate material. 
     The housing  104  also includes a first panel  210  and a second panel  212 . As shown in  FIG.  3   , the first and second panels  210 ,  212  are part of the body portion  200  (e.g., the first and second panels  210 ,  212  and the body portion  200  are a monolithic structure). For example, as shown in  FIG.  3   , bridge portions  300 ,  302  join the first and second panels  210 ,  212 , respectively, to the body portion  200 . Alternatively, the first and second panels  210 ,  212  may be separate from the body portion  200 . In such cases, the joint structures  206  may couple the panels  210 ,  212  to the body portion  200 . 
     Returning to  FIG.  2   , exterior surfaces of the joint structures  206  may form a continuous surface with exterior surfaces of the housing  104 . Alternatively, the exterior surfaces of the joint structures  206  may be recessed from or proud of portions of the housing that are adjacent the joint structures  206 . Further, the exterior surfaces of the joint structures  206  may be configured to blend in with other portions of the housing  104 . For example, the joint structures  206  may be the same color as nearby portions of the housing  104 , may have the same surface finish/texture as exterior portions of the housing  104 , or the like. The joint structures  206  may also be formed from the same material as the body portion  200  and the end portions  202 ,  204 . In some cases, however, the joint structures  206  have a different color or surface finish than exterior portions of the housing  104 . 
     The body portion  200  and/or the end portions  202 ,  204  may be part of an electrical circuit of the device  100 . For example, one or both of the end portions  202 ,  204  may be an antenna, or a portion of an antenna, for wireless communication (e.g., cellular, Wi-Fi, Bluetooth, and so on). Where an end portion is an antenna, or is otherwise part of an electrical circuit, it may be necessary or desirable to electrically and/or capacitively isolate one or both of the end portions from other portions of the housing  104 , such as the body portion  200 . Accordingly, the joint structures  206  may be formed from an electrical insulator that electrically and/or capacitively isolates and/or insulates the housing components from each other while also coupling them together to form a structurally sound housing  104 . 
       FIG.  3    shows a partial exploded view of the housing  104 , with the end portions  202 ,  204  separated from the body portion  200 . As described herein, the joint structures  206  (shown in  FIG.  2   , not shown in  FIG.  3   ) couple the end portions  202 ,  204  to the body portion  200 . Also shown in  FIG.  3    are bridge portions  300 ,  302  that join the first and second panels  210 ,  212 , respectively, to the body portion  200 . The bridge portions  300 ,  302  are recessed relative to an exterior surface of the body portion  200 , forming grooves in the body portion  200  that receive portions of the joint structures (e.g., the second molded elements  600 ,  FIG.  6   ). 
       FIGS.  4 - 6    show various views of an embodiment of the housing  104  in which the joint structures  206  each include two molded elements. For example, with reference to  FIGS.  4 - 5   , first molded elements  400  (e.g.,  400 - 1  and  400 - 2 ) are disposed at least partially within gaps between the top and bottom portions  202 ,  204  and the body portion  200 , and couple the top and bottom portions  202 ,  204  to the body portion  200 . The molded elements described herein may be formed by molding (including, for example, injecting) a material into the gaps between components of the housing  104 . However, the molded elements, or portions thereof, may be formed in other ways as well, and are not necessarily limited to any particular manufacturing or forming process. For example, one or more of the molded elements may be formed separately from the housing  104  (using any appropriate process, such as extruding, machining, or the like) and positioned in the gaps after the molded elements are formed. 
     As shown in  FIGS.  4  and  5   , the first molded elements  400  do not extend to the exterior surfaces of the housing  104 . Rather, the first molded elements  400  only partially fill the gaps between the housing portions, leaving recesses  414  (e.g.,  414 - 1  and  414 - 2 ,  FIG.  5   ) into which second molded elements  600  (e.g.,  600 - 1  and  600 - 2 ,  FIG.  6   ) are then formed, filling the remaining portions of the gaps and forming part of the exterior surface of the housing  104 .  FIGS.  4 - 5    show the housing  104  with only the first molded elements  400  disposed in the gaps between the housing portions.  FIG.  6    shows the front of the housing  104  with both the first molded elements  400  and the second molded elements  600  formed in the gaps. 
     The first molded elements  400  may couple the housing portions together by mechanically engaging with interlock features of the housing portions, as described herein. The second molded elements  600  couple to the housing  104  (and/or to the first molded elements  400 ) by mechanically engaging with interlock features of the housing  104  and/or the first molded elements  400 , as discussed herein. 
     While the molded elements are described herein as being formed in or within the gaps between housing components, the molded elements may extend beyond the gaps and may couple to, cover, lie flush with, or otherwise engage with other portions of the housing  104 . For example, as illustrated in  FIG.  4   , the first molded elements  400  include portions that cover part of an interior surface of the housing  104 . Thus, some portions of the molded elements may be disposed within gaps between housing components, whereas other portions are disposed outside the gaps. Moreover, the molded elements of each joint structure  206  are shown and described as being single, monolithic components. More molded elements (e.g., several discrete molded elements) may be used to form any joint structure  206 , however. 
     As noted above, the first and second molded elements may each benefit from, or otherwise employ, a different set of material properties. For example, the first molded elements  400  may provide the primary (or sole) mechanical coupling between housing portions. Accordingly, a material having a high yield strength, stiffness, and/or toughness (as compared to the material for the second molded elements  600 , or even the housing  104 , for example) may be selected to create the first molded elements  400 . Additionally, the housing  104  may be subjected to certain processing steps after the housing portions are joined by the first molded elements  400 , such as anodizing, annealing, or the like. In such cases, a material that is able to resist degradation or damage when subjected to anodizing, heating, or other chemical or physical processes may be selected for the first molded elements  400 . For example, the first molded elements  400  may be formed from glass fiber reinforced nylon, glass fiber reinforced polyether ether ketone, or the like. 
     Different material properties may be useful for the second molded elements  600 . For example, because the second molded elements  600  form part of the exterior surface of the housing  104 , a material having a high chemical resistance may be selected, so that the material does not degrade when it comes into contact with potentially corrosive materials such as cleaning agents, sweat, water, alcohol, or the like. If the housing  104  is to be processed after the second molded elements  600  are formed, a material that can withstand anodizing processes, heating, or polishing may be selected. For example, after the housing  104  is formed, including forming both the first and second molded elements  400 ,  600 , the exterior surface of the housing  104  may be polished. Thus, the second molded elements  600  typically withstand such a polishing process and also take on a smooth, polished surface itself. 
     The material may also be selected based on its ability to be pigmented or dyed to certain colors. For example, a dark material may not be able to be colored to a shade of white, which may be desirable for some housings. Also, because the second molded elements  600  form cosmetic surfaces of the housing  104 , it may be preferable for the material to dent or deform slightly, rather than crack or shatter, when the device  100  is dropped or otherwise subjected to a potentially damaging force. Thus, a material that is not prone to brittle failure may be selected for the second molded elements  600 . Non-limiting examples of materials that may be used to form the second molded elements  600  include polyether ether ketone, polysulfone, polyphenylsulfone, polyaryletherketone, polyetherimide, and polyethersulfone. 
       FIG.  7    is a partial cross-sectional view of the housing  104  taken along line  7 - 7  in  FIG.  4   , illustrating how a boss  408  mechanically engages the first molded element  400 - 1  to couple the top portion  202  to the first molded element  400 - 1 . The mechanical engagement between the boss  408  (and/or a screw  702  held by the boss) and the first molded element  400 - 1  couples the top portion  202  to the first molded element  400 - 1 . Because the first molded element  400 - 1  is also coupled to the body portion via other interlock features, as described herein, the engagement between the boss  408  and the first molded element  400 - 1  results in the top portion  202  being coupled to the body portion  200 . 
     A recess  704  receives the second molded element (not shown) that forms a portion of the exterior surface of the housing  104 . The first molded element  400 - 1 , as molded, may form a bottom surface of the recess  704  (e.g., the first molded element  400 - 1  is molded to its final shape, which at least partially defines the recess, in a single molding or forming process). Alternatively, the first molded element  400 - 1  may be processed after molding to form the recess  704 . For example, after material is introduced into the gap to form the molded element  400 - 1 , the material may partially or completely occupy the recess  704 , and subsequent processing (e.g., grinding, milling, laser ablation, and the like) may be used to remove material from the first molded element  400 - 1  to form the recess  704 . 
     The boss  408  includes an angled surface  700  that forms an undercut engaging the first molded element  400 - 1 . In particular, when the material forming the first molded element  400 - 1  is molded into the gap between the top portion  202  and the body portion  200 , the material flows into the space under the angled surface  700 . Once the material hardens, the angled surface  700  prevents the first molded element  400 - 1  from horizontally separating from the top portion  202  (with respect to the orientation shown in  FIG.  7   ). Other interlock features and/or structural components may prevent the first molded element  400 - 1  and the top portion  202  from moving vertically relative one another, increasing the effectiveness of the angled surface  700  in retaining the first molded element  400 - 1  and the top portion  202 . For example, threads of the screw  702  (described herein) may prevent the top portion  202  from moving vertically relative to the first molded element  400 - 1  (with respect to the orientation shown in  FIG.  7   ). 
     As noted above, a screw  702  may be threaded into or otherwise secured in a through-hole  410  of the boss  408 . The screw  702  extends below the angled surface  700  and into the first molded element  400 - 1 , thus acting as an interlock feature to prevent the first molded element  400 - 1  and the top portion  202  from moving horizontally (and vertically) with respect to one another. While  FIG.  7    depicts a screw, similar functionality may be provided by a smooth post, a splined post, or any other appropriate feature that extends below the angled surface  700  and engages the first molded element  400 - 1 . 
     The boss  408  need not include both the angled surface  700  and the screw  702 . For example, the boss  408  may have a horizontal surface in place of the angled surface  700  (or a surface angled in an opposite or another direction than the angled surface  700 ). In such embodiments, the boss  408  may provide mechanical engagement between the top portion  202  and the first molded element  400 - 1  by the screw  702  alone. Alternatively, the boss  408  may omit the through-hole  410  and the screw  702  entirely, and mechanically engage with the first molded element  400 - 1  solely with the angled surface  700  or with any other appropriate shape or feature. 
     In addition to forming an interlock feature that mechanically engages the first molded element  400 - 1 , the boss  408  and/or the screw  702  may act as an electrical contact point to couple the top portion  202  to an electrical component of the device  100 . For example, where the top portion  202  is an antenna (or part of an antenna), an electrical connector that is electrically coupled to a radio circuit or component may be coupled to the boss  408  by the screw  702 . Thus, the top portion  202  may be electrically coupled to the radio circuit or component. The bottom portion  204  may include a similar boss to electrically couple the bottom portion  204  to electrical components of the device  100 . 
       FIG.  8    is a partial cross-sectional view of the housing  104  taken along line  8 - 8  in  FIG.  4   , illustrating various interlock features that may couple the top portion  202  and/or the body portion  200  to the first molded element  400 - 1 . The top portion  202  includes a post  800  that extends vertically from a surface. During forming of the first molded element  400 - 1 , the material of the first molded element  400 - 1  flows around the post  800 . When the material hardens, the first molded element  400 - 1  at least partially surrounds the post  800 , and the first molded element  400 - 1  is thus prevented from moving horizontally with respect to the top portion  202  (as oriented in  FIG.  8   ). 
     The post  800  may have any appropriate shape and/or cross-section. For example, the post  800  may have a circular (e.g., a cylindrical post), square, rectangular, or triangular cross-section, or any other appropriate cross-section. Moreover, the post (and/or any associated supporting structures) may be formed in any appropriate way. For example, the top portion  202  may include the post  800  as-cast or as-molded. More particularly, a mold that is used to form the top portion  202  may be configured to produce a net (or near-net) shape top portion  202  that includes the post  800 . As another example, the post  800  may be machined into the top portion  202 . As yet another example, the post  800  may be formed by laser sintering material onto the top portion  202  to form the post  800  (e.g., using a laser to sinter powdered material that is built-up on a surface) or bonding a post to the top portion  202 . As yet another example, the post  800  may be a separate component that is screwed, threaded, or otherwise attached to the top portion  202 . 
     Like the top portion  202 , the body portion  200  may also include an interlock feature that engages the first molded element  400 - 1 . For example, the body portion  200  may include an angled protrusion  802  that extends away from a surface of the body portion  200  and engages the first molded element  400 - 1 . (Instead of or in addition to the angled protrusion  802 , the body portion  200  may include any other protrusion or interlock feature, such as a post, a cavity, a screw, or the like.) The mechanical engagement between the angled protrusion  802  and the first molded element  400 - 1  prevents or limits the first molded element  400 - 1  from moving horizontally relative to the body portion  200 . The angled protrusion  802  may be formed in any appropriate manner, such as molding, machining, laser sintering, bonding (e.g., adhering an additional component to the body portion  200 ) or the like. 
       FIG.  9    is an expanded view of area  412  of  FIG.  4   , illustrating a dovetail-type interlock feature that couples the first molded element  400 - 1  to the body portion  200 . The body portion  200  of the housing includes a dovetail-shaped recess  900 . When the material of the first molded element  400 - 1  is introduced into the gaps, the material may also be introduced into the dovetail-shaped recess  900 . Once the material is cured, the first molded element  400 - 1  forms a dovetail  902  that is disposed in the recess  900 , and mechanically couples the first molded element  400 - 1  to the body portion  200 . 
       FIGS.  7 - 9    illustrate interlock features that may be used to couple both the top portion  202  and the body portion  200  to the first molded element  400 - 1 . Thus, the first molded element  400 - 1  effectively couples the top portion  202  to the body portion  200  to form the housing  104 . The same or similar interlocks may be used to couple the bottom portion  204  to the body portion  200  using the first molded element  400 - 2  of the joint structure  206 - 2 . 
     As noted above, the second molded elements  600  are formed in the recesses  414  and are coupled to the first molded elements  400  and/or portions of the housing  104 . For example, the second molded elements  600  may mechanically engage interlock features of the first molded elements  400  or the housing  104 .  FIGS.  4  and  6    illustrate one example interlock feature that may be used to couple the first and second molded elements. In particular, the first molded elements  400  may include cavities  404  ( FIG.  4   ) into which the second molded elements  600  may be formed. The cavities  404  communicate with the recesses  414  via an opening that is narrower (or otherwise smaller) than the cavity. Portions of the second molded elements  600  that are formed in the cavities  404  are thus held captive in the cavities  404 , preventing the second molded elements  600  from decoupling or being pulled away from the first molded elements  400  and the housing  104 . 
       FIG.  10    is a partial cross-sectional view of the housing  104  taken along line  10 - 10  in  FIG.  6   , illustrating other examples of interlock features that mechanically engage the second molded element  600 - 2  to the housing  104 . The body portion  200  includes a protrusion  1000  that extends away from a surface of the body portion  200  and into a cavity in which the second molded element  600 - 2  is disposed. During forming of the second molded element  600 - 2 , the material of the second molded element  600 - 2  flows around the protrusion  1000 . When the material hardens, the second molded element  600 - 2  mechanically engages the second molded element  600 - 2 . In particular, the second molded element  600 - 2  is prevented from moving at least vertically with respect to the body portion  200  (as oriented in  FIG.  10   ). Accordingly, the second molded element  600 - 2  is retained to the housing  104  via the protrusion  1000 . The protrusion  1000  may have any appropriate shape and/or cross-section, such as a circular, square, rectangular, or triangular cross-section, or any other appropriate shape or cross section. 
       FIG.  11    is a partial cross-sectional view of the housing  104  taken along line  11 - 11  in  FIG.  10   . In the embodiment shown, the protrusion  1000  is solid. In other embodiments, the protrusion may include one or more through-holes (or other cavities, recesses, or the like) that provide additional mechanical engagement between the body portion  200  and the second molded element  600 - 2 . 
       FIG.  12    is a partial cross-sectional view of the housing  104  taken along line  10 - 10  in  FIG.  6   , illustrating an embodiment of the housing  104  where a protrusion  1200  includes a through-hole  1202  into which part of the second molded element  600 - 2  is disposed. In particular, material may flow into the through-hole  1202  during the forming of the second molded element  600 - 2 .  FIG.  13    is a partial cross-sectional view of the housing  104  taken along line  13 - 13  in  FIG.  12   , showing another view of the protrusion  1200  and the through-hole  1202 . The additional mechanical engagement provided by the through-hole  1202  may increase the security of the coupling between the second molded element  600 - 2  and the body portion  200 . For example, while the protrusion  1000  ( FIG.  10   ) may primarily prevent or limit vertical motion of the second molded element  600 - 2  (as oriented in  FIG.  12   ), the protrusion  1200  may prevent or limit both vertical and horizontal motion of the second molded element  600 - 2  with respect to the body portion  200 . 
       FIG.  14    is a partial cross-sectional view of another embodiment of the housing  104  taken along line  10 - 10  in  FIG.  6   , illustrating another example of an interlock feature with which the second molded element  600 - 2  engages to couple the second molded element  600 - 2  to the housing  104 . In the illustrated embodiment, the bottom portion  204  includes a recess  1400  into which a portion of the second molded element  600 - 2  protrudes. In particular, the material of the second molded element  600 - 2  may flow into the recess  1400  during forming of the second molded element  600 - 2 , and then harden to form a secure mechanical engagement with the recess  1400 . 
     The recess  1400  may have any appropriate shape, and may be configured to retain the second molded element  600 - 2  in the gap by preventing the second molded element  600 - 2  from moving vertically with respect to the housing  104  (as oriented in  FIG.  14   ). The recess  1400  may be any appropriate length along the bottom portion  204 . For example, the recess  1400  may have similar length and height dimensions (where height is vertical and length is into/out of the page), or it may have a channel-shape where the length is longer than the height. In some cases, the recess  1400  may form a channel that extends along substantially an entire surface of the bottom portion  204 . 
     The recess  1400  may be formed in any appropriate manner. For example, the recess  1400  may be part of the bottom portion  204  as-cast or as-molded, without requiring additional post-processing steps to form the recess  1400 . Alternatively, the recess  1400  may be formed into the bottom portion  204  by drilling, milling, machining, laser ablating, or any other appropriate process. 
       FIG.  15    is a partial cross-sectional view of another embodiment of the housing  104  taken along line  10 - 10  in  FIG.  6   , illustrating an example of another interlock feature with which the second molded element  600 - 2  may engage to couple the second molded element  600 - 2  to the housing  104 . In  FIG.  15   , the bottom portion  204  includes a slot  1500  into which a portion of the second molded element  600 - 2  protrudes. In particular, the material of the second molded element  600 - 2  may flow into the slot  1500  during forming of the second molded element  600 - 2 , and then harden within the slot to mechanically engage the second molded element  600 - 2  to the bottom portion  204 . The slot  1500  may have any appropriate shape, and functions similar to the recess  1400  to retain the second molded element  600 - 2  in the gap between the housing components. Moreover, the slot  1500  may be formed in any appropriate way and using any appropriate technique, such as by molding or casting the bottom portion  204  to include the slot  1500 , or forming the slot  1500  by milling, machining, laser ablating, grinding, or any other appropriate process. 
       FIGS.  16 A- 16 C  are partial cross-sectional views of another embodiment of the housing  104  taken along line  10 - 10  in  FIG.  6   , illustrating an example of an interlock feature with which the second molded element  600 - 2  may engage to couple the second molded element  600 - 2  to the first molded element  400 - 2 . In the illustrated embodiment, the second molded element  600 - 2  is retained to the housing  104  at least partially via a mechanical interlock with the first molded element  400 - 2 . A mechanical interlock between the second molded element  600 - 2  and the first molded element  400 - 2  may be used instead of or in addition to mechanical interlocks between the second molded element  600 - 2  and the bottom portion  204  and/or the body portion  200  of the housing  104  (e.g. such as those discussed above with respect to  FIGS.  10 - 15   ). 
     With reference to  FIG.  16 C , the first molded element  400 - 2  includes a tapered through-hole  1602  into which material of the second molded element  600 - 2  flows during forming of the second molded element  600 - 2 . Once the material hardens, the tapered profile of the through-hole  1602  holds the second molded element  600 - 2  captive to the first molded element  400 - 2 , and thus retains the second molded element  600 - 2  to the housing  104 . 
       FIGS.  16 A- 16 B  illustrate stages of an example manufacturing process for forming the interlock shown in  FIG.  16 C . In  FIG.  16 A , the first molded element  400 - 2  is formed between the bottom portion  204  and the body portion  200 . Forming the first molded element  400 - 2  may include flowing the material into a gap between the bottom portion  204  and the body portion  200 . Prior to flowing the material into the gap, a removable insert may be placed into a region where the through-hole  1602  is to be located. When the material is flowed into the gap, it flows around the removable insert. Once the material has at least partially hardened or cured, the removable insert may be removed, forming a blind hole  1600  in the first molded element  400 - 2 , as shown in  FIG.  16 A . The removable insert may have a draft angle that facilitates removal of the insert from the first molded element  400 - 2 . This same draft angle forms the tapered profile of the through-hole  1602  that retains the material of the second molded element  600 - 2  to the first molded element  400 - 2 . 
     A portion  1604  of the first molded element  400 - 2  at the blind end of the hole  1600  is then removed in order to create the through-hole  1602 . Removing this material may also create or deepen a recess  1606  in the exterior surface of the housing  104  into which the second molded element  600 - 2  is formed. The material may be removed using machining, grinding, abrasive blasting (e.g., sand blasting), laser ablation, laser cutting, or the like.  FIG.  16 B  illustrates the first molded element  400 - 2  after the portion  1604  has been removed. 
     Once the material is removed to form the through-hole  1602  and the recess  1606 , the material forming the second molded element  600 - 2  may be introduced into the recess  1606  between the bottom portion  204  and the body portion  200  such that the material flows at least partially into the through-hole  1602 . Once the material of the second molded element  600 - 2  hardens, the mechanical engagement between the tapered walls of the through-hole  1602  and the corresponding tapered surfaces of the second molded element  600 - 2  retains the second molded element  600 - 2  to the first molded element  400 - 2  and within the recess  1606 . 
     The second molded element  600 - 2  may be molded proud of the body portion  200  and the bottom portion  204 . Accordingly, material may be removed from the second molded element  600 - 2  to form a substantially uninterrupted, seamless, and/or smooth transition between the second molded element and neighboring exterior surfaces of the housing  104 , for example, by grinding, machining, polishing, sanding, abrasive blasting, or laser ablating the second molded element  600 - 2 . In some locations of the housing  104 , the second molded element  600 - 2  and one or more nearby surfaces of the housing  104  form a substantially coplanar exterior surface of the housing  104 . For example, in the area  214  in  FIG.  2   , the second panel  212 , the joint structure  206 - 2  (which may include the second molded element  600 - 2 ), and the body portion  200  may be substantially coplanar. Moreover, the seams between the components in this area (and indeed between any of the joint structures  206  and adjacent housing portions) may lack gaps, grooves, or other surface discontinuities or irregularities, such that the exterior surface of the housing  104  is a continuous and/or smooth surface. 
       FIGS.  17 A- 17 C  are partial cross-sectional views of another embodiment of the housing  104  taken along line  10 - 10  in  FIG.  6   , illustrating another example of an interlock feature with which the second molded element  600 - 2  may engage to couple the second molded element  600 - 2  to the first molded element  400 - 2 . In the illustrated embodiment, the second molded element  600 - 2  is retained to the housing  104  at least partially with a threaded interlock feature  1700  in the first molded element  400 - 2  ( FIG.  17 B ). The threaded interlock in  FIGS.  17 A- 17 C  may replace or supplement mechanical interlocks between the second molded element  600 - 2  and the housing  104  (e.g., such as those described with respect to  FIGS.  10 - 15   ). 
     With reference to  FIG.  17 B , the first molded element  400 - 2  includes a threaded hole  1700  into which material of the second molded element  600 - 2  flows during forming of the second molded element  600 - 2 . Once the material hardens, the threads of the threaded hole  1700  engage the material of the second molded element  600 - 2 , thereby retaining the second molded element  600 - 2  to the first molded element  400 - 2  and, therefore, the housing  104 . While  FIGS.  17 B- 17 C  show a threaded hole  1700 , a hole may include interlock features other than threads, such as grooves, splines, undercuts, recesses, cavities, protrusions, or the like. 
       FIGS.  17 A- 17 B  illustrate stages of an example manufacturing process for forming the threaded interlock shown in  FIG.  17 C . In  FIG.  17 A , the first molded element  400 - 2  has been formed between the bottom portion  204  and the body portion  200 . Forming the first molded element  400 - 2  may include flowing the material against or around interlock features of the bottom portion  204 , the body portion  200 , and/or other portions of the housing  104  to retain the first molded element  400 - 2  to the housing  104 , as described herein. 
     A threaded hole  1700  is then formed in the first molded element  400 - 2 . The threaded hole  1700  may be a blind hole (as shown), or it may be a through-hole. The threaded hole  1700  may be formed in any appropriate way. For example, a smooth-bore hole may be formed by drilling, milling, chemical etching, laser ablating, or the like. Threads may then be cut into the sidewall of the smooth hole with a tapping tool or other appropriate tool or process. 
     Instead of forming the threaded hole  1700  after forming the first molded element  400 - 2 , the first molded element  400 - 2  may include the threaded hole  1700  in its as-formed shape. For example, a threaded insert may be placed into the region between the bottom portion  204  and the body portion  200  where the threaded hole  1700  is to be located. The material forming the first molded element  400 - 2  is then flowed into the space and around the threaded insert. Once the material has at least partially hardened or cured, the threaded insert may be removed by unthreading the insert from the first molded element  400 - 2 , leaving the threaded hole  1700  in the first molded element  400 - 2 . 
     Once the threaded hole  1700  is formed, the material forming the second molded element  600 - 2  may be introduced into a recess  1702  between the bottom portion  204  and the body portion  200  such that the material flows at least partially into the threaded hole  1700 . Once the material hardens, the mechanical engagement between the threads of the threaded hole  1700  and the corresponding threaded surfaces of the second molded element  600 - 2  retain the second molded element  600 - 2  to the first molded element  400 - 2  and within the recess  1702 . In some cases, the second molded element  600 - 2  is molded proud of neighboring exterior surfaces of the body portion  200  and the bottom portion  204  and is further processed to form a substantially uninterrupted, seamless, and/or smooth transition between the second molded element  600 - 2  and neighboring exterior surfaces of the housing  104 , as described above. 
       FIG.  17 D  is a partial cross-sectional view of another embodiment of the housing  104  taken along line  10 - 10  in  FIG.  6   , illustrating a combination of interlock features that together couple the second molded element  600 - 2  to the housing  104  (e.g., the bottom portion  204 ), couple the second molded element  600 - 2  to the first molded element  400 - 2 , and couple the second molded element  600 - 2  to the housing  104  (e.g., the bottom portion  204 ). In particular, the first molded element  400 - 2  engages an undercut  1710  in the bottom portion  204  of the housing  104 . The undercut  1710  prevents the first molded element  400 - 2  from horizontally separating from the bottom portion  204  (with respect to the orientation shown in  FIG.  17 D ), and also thereby couples the bottom portion  204  to the body portion  200 . 
     The second molded element  600 - 2  is molded into a cavity that is formed partially by the first molded element  400 - 2  (e.g., the wall  1708 ) and partially by the bottom portion  204  of the housing  104  (e.g., the wall  1706 ). Thus, the interlock feature is formed by both the housing  104  and the first molded element  400 - 2 . The angle of the walls  1706 ,  1708  prevent the second molded element  600 - 2  from vertically separating from the first molded element  400 - 2  (with respect to the orientation shown in  FIG.  17 D ). The walls  1706 ,  1708  may be formed in any appropriate manner. For example, they may be machined into the bottom portion  204  and the first molded element  400 - 2  after the first molded element  400 - 2  is molded into the gap between the bottom portion  204  and the body portion  200 . 
     The geometry of the walls  1706 ,  1708  as shown in  FIG.  17 D  are merely examples, and any other geometries or interlocks that are formed by both the first molded element  400 - 2  and the housing  104  may be used. For example, instead of the angled walls  1706 ,  1708 , the interlock may be a threaded hole that is formed partly in the bottom portion  204  of the housing  104 , and partly in the first molded element  400 - 2 . For example, after the first molded element  400 - 2  is molded, a hole may be drilled and threaded at an interface between the first molded element  400 - 2  and the bottom portion  204  of the housing  104 . The resulting threaded hole is defined in part by the bottom portion  204  and in part by the first molded element  400 - 2 . 
     The second molded element  600 - 2  may also be coupled to the housing  104  via an interlock feature formed in the housing  104  alone. For example, the bottom portion  204  of the housing  104  includes a slot  1704  into which a portion of the second molded element  600 - 2  protrudes. In particular, the material of the second molded element  600 - 2  may flow into the slot  1704  during forming of the second molded element  600 - 2 , and then harden within the slot to mechanically engage the second molded element  600 - 2  to the bottom portion  204 . 
     While  FIG.  17 D  illustrates a combination of interlock features, it is merely one example combination of features that may be used. For example, the slot  1704  may be replaced (or supplemented) by any other interlock feature that is formed in the housing  104  to couple to the second molded element  600 - 2  (e.g., the recess  1400  in  FIG.  14   ). Similarly, the undercut  1710  may be replaced (or supplemented) by any other interlock feature that is configured to couple the first molded element  400 - 2  to the housing  104  (e.g., the boss  408  in  FIGS.  4 ,  7   ). Moreover, any of the interlock structures shown in  FIG.  17 D  may be used independently of any others. 
     Instead of or in addition to the interlocks described above for coupling the second molded element  600 - 2  to the first molded element  400 - 2 , first and second molded elements may be coupled to one another by adhesion. For example, an adhesive may be applied to the first molded elements  400  (e.g., on the surfaces of the first molded elements that form the bottoms of the recesses  414 ) before the second molded elements  600  are molded into the recesses  414 . Thus, the second molded elements  600  may adhere to the first molded elements  400  with the adhesive. As another example, a solvent may be applied to the first molded elements  400  to allow the second molded elements  600  to chemically bond directly to the first molded elements  400 . As yet another example, the material of the second molded elements  600  may be configured to chemically attack the surface of the first molded elements  400  such that the materials of the first and second molded elements cure together to form a monolithic structure. As yet another example, the first molded elements  400  may be processed to form a rough or textured surface (e.g., by sanding, sand blasting, grinding, laser ablating, chemical etching, or the like) that facilitates adhesion between the first and second molded elements. Similarly, nano-molding technology may be used to form small (e.g., nano-scale or micro-scale) features on the surfaces of the first molded elements  400 , to which the second molded elements  600  anchor when molded over the first molded elements  400 . The foregoing techniques may also be used to facilitate adhesion between portions of the housing  104  (e.g., the top and bottom portions  202 ,  204  and the body portion  200 ) and the first and second molded elements. 
     The interlock features described above, as well as their locations on the various housing components and joint structures, are examples. Embodiments may use various different combinations of the interlock features described, may place the interlock features in locations other than those described or depicted herein, and/or may use multiple instances of (or omit) any of the interlock features described. For example, interlock features described as being part of the top portion  202  may instead or additionally be part of the body portion  200 . Moreover, interlock features that are described above for coupling a second molded element  600  to a first molded element  400  may instead or in addition be used to couple a first molded element  400  to the housing  104 . Such variations are within the scope of the ideas presented herein. 
       FIGS.  7 - 17 D , described above, illustrate various interlock features that may be used to couple joint structures to a housing of an electronic device, and to couple various portions of a housing together to form a complete housing structure. Joint structures may also include features that help strengthen or buttress more delicate or more critical portions of the joint structures, and to help increase the overall durability and structural integrity of the housing. 
       FIG.  18    is a partial exploded view of the housing  104  showing the joint structure  206 - 1  where the second molded element  600 - 1  is removed from the first molded element  400 - 1 . The body portion  200  and the top portion  202  each include a flange  1800 ,  1802 , respectively. The flanges of the housing portions define a frame that is adapted to receive a transparent cover (e.g., a glass or plastic component, or an assembly including multiple layers of glass, plastic, coatings, or the like) of the device  100 . The second molded element  600 - 1  includes a tooth  1804  or other member or protrusion that extends past a ledge  1806  of the second molded element and bridges a gap between the flanges  1800  and  1802 , thus forming a portion of the frame. The second molded element  600 - 1  also includes a guide structure (or support structure)  1808  that supports and/or strengthens the tooth  1804  (or other member or protrusion), and is configured to bias the second molded element  600 - 1  towards an interior of the housing  104  to prevent or reduce damage to the second molded element  600 - 1  in the event of an impact. 
     In  FIG.  18   , the guide structure  1808  protrudes from a side of the second molded element  600 - 1  (or both sides, as shown). The cavity  404  ( FIG.  4   ) in first molded element  400 - 1  includes a corresponding shape or feature into which the guide structure  1808  is disposed when the first and second molded elements are coupled together. In particular, because the second molded element  600 - 1  is molded into the gap between the housing components and into the cavity  404 , the shape of the recess and the cavity  404  will determine the shape of the second molded element  600 - 1 , including the guide structure  1808 . Thus, the guide structure  1808  (and indeed any of the guide structures described herein) may be formed by the process of molding the second molded element  600 - 1  into the gap between the housing components and against the first molded element  400 - 1 . 
     By including the guide structure  1808  near the tooth  1804 , the tooth  1804  (or other member or protrusion) may be stronger and more resistant to breakage than if no guide structure were included (e.g., if the portion of the second molded element  600 - 1  that extends from the tooth  1804  to the ledge  1806  was the same width as the tooth  1804 ). For example, when the device  100  is dropped or otherwise subjected to an impact, the top portion  202  and the body portion  200  may be pressed together, thus narrowing the gap between the components and resulting in the joint structure  206 - 1  being compressed. This narrowing of the gap and resulting compression on the joint structure  206 - 1  may cause the tooth  1804  to crack, break, or otherwise become damaged. The addition of the guide structure  1808  near the tooth  1804  increases the strength of the second molded element  600 - 1  in the vicinity of the tooth  1804 , and thus may reduce the likelihood of or prevent damage to the tooth  1804  in the event of a drop or other potentially damaging impact. 
     Also, the guide structure  1808  may act as a guide such that when the second molded element  600 - 1  is compressed between the housing components as a result of the narrowing of the gap between the housing components, the tooth  1804  (or other member or protrusion) is drawn or biased towards the interior of the housing  104 , as shown by arrow  1810 , rather than forced outwards, towards the exterior of the housing  104 . In particular, if the tooth  1804  is forced outwards, it may be more likely to break than if it is drawn towards the interior of the housing  104 . Thus, when the housing portions are forced together, the sides of the cavity  404  of the first molded element  400 - 1  will press against the guide structure  1808 . Because the guide structure  1808  is wider at the end near the interior of the housing  104 , the pressure against the guide structure  1808  will result in the tooth  1804  (and surrounding areas) being forced toward the housing  104  in the direction of the arrow  1810 . 
     It is not necessary that the tooth  1804  actually moves or deflects toward the interior of the housing  104  for the guide structure  1808  to be effective. Indeed, as the second molded element  600 - 1  may be rigidly held in the gap between the housing components, it may be unable to move freely. Nevertheless, the shape of the guide structure  1808  translates a compression force into an inward force rather than an outward force, the latter being more likely to result in damage to the tooth  1804 . 
       FIG.  19    is a partial exploded view of the housing  104  showing the joint structure  206 - 1  where the second molded element  600 - 1  is removed from the first molded element  400 - 1 . A guide structure (or support structure)  1900  protrudes from a side of the second molded element  600 - 1 . The guide structure  1900  has a rounded shape that is similar to the guide structure  1808 , but does not extend to a top surface of the ledge  1806 . The guide structure  1900  strengthens the tooth  1804  and tends to draw the tooth  1804  towards the interior of the housing  104 , as described with respect to the guide structure  1808 . 
     The first molded element  400 - 1  includes a pocket  1902  in which the guide structure  1900  is disposed when the first and second molded elements are coupled together to form the joint structure  206 - 1 . The pocket  1902  includes an undercut in the material of the first molded element  400 - 1 , and communicates with the cavity  404 . The pocket  1902  may be molded into the first molded element  400 - 1  during forming of the first molded element  400 - 1 , or it may be formed by machining, grinding, laser ablating, or otherwise removing material from the first molded element  400 - 1  after it is formed. The guide structure  1900  may be formed during the molding of the second molded element  600 - 1  by introducing material into the gap between the housing portions and into the cavity  404  and the pocket  1902 . The cured material forms the second molded element  600 - 1 , and the guide structure  1900  mechanically engages the pocket  1902 . 
       FIGS.  20 A- 20 C  illustrate another embodiment of a guide structure (or support structure)  2000  that protrudes from a side of the second molded element  600 - 1  to support the tooth  1804 . The guide structure  2000  extends from a side of the tooth  1804  to a side of the ledge portion  1806 , and is configured to be disposed in a pocket  2002  in the housing  104 . The pocket  2002  may be formed from cavities in both the first molded element  400 - 1  and the housing  104  (e.g., the top portion  202  and/or the body portion  200 ). In particular, a portion of the pocket  2002  may be formed in the top portion  202  of the housing  104 , and a second portion of the pocket  2002  may be formed in the first molded element  400 - 1 . The first and second portions communicate with each other to form a single pocket  2002  in which the guide structure  2000  is formed. The pocket  2002  and the guide structure  2000  may form a rounded bevel shape. For example, an outer edge of the guide structure  2000  may extend along a rounded path from a curved member  2004  to the ledge portion  1806 . Moreover, a top surface of the guide structure  2000  (as oriented in  FIG.  20 B ) may extend away from the curved member  2004  and from a top surface of the ledge portion  1806  at an angle, while a bottom surface of the guide structure extends substantially parallel to a top surface of the ledge portion  1806 . 
     The pocket  2002  may be formed by removing material from the housing portions and the first molded element  400 - 1  (e.g., by grinding, cutting, machining, or the like) after the first molded element  400 - 1  is formed. The guide structure  2000  may be formed during the molding of the second molded element  600 - 1  by introducing material into the gap between the housing portions and into the cavity  404  and the pocket  2002 . The cured material forms the second molded element  600 - 1 , and the guide structure  2000  mechanically engages the pocket  2002 . 
       FIG.  21 A  is a partial exploded view of the housing  104  showing the joint structure  206 - 1  where the second molded element  600 - 1  is removed from the first molded element  400 - 1 .  FIG.  21 B  is a partial view of the second molded element  600 - 1  in which a gusset  2100  is disposed on an interior radius of a curved member  2104  of the second molded element  600 - 1 . The gusset  2100  is configured to be disposed within a groove  2102  formed in the first molded element  400 - 1 . The gusset  2100  may strengthen and/or support the curved member  2104  and the tooth  1804  by increasing the amount of material available to support stresses imparted on those portions of the second molded element  600 - 1 . Moreover, the gusset  2100  may stiffen the curved member  2104  such that compression of the second molded element  600 - 1  (e.g., caused by dropping the device  100 ) does not result in damaging deflection of the curved member  2104  and/or the tooth  1804 . 
     Like other features described herein, the groove  2102  may be molded directly into the first molded element  400 - 1 , or formed after molding by removing material by grinding, milling, laser ablating, or the like. Moreover, the gusset  2100  may be formed by molding the material of the second molded element  600 - 1  into the groove  2102 . 
       FIGS.  22 A- 22 B  illustrate another example of a gusset  2200  that may support a curved member  2204  of the second molded element  600 - 1 . Whereas the gusset  2100  ( FIGS.  21 A-B ) extends only part of the width of the curved member  2104 , the gusset  2200  in  FIG.  22 B  extends the full width of the curved member  2204 . 
       FIGS.  23 A- 23 B  illustrate an embodiment of the second molded element  600 - 1  that includes a chamfer  2300  at a joint between the tooth  1804  and the ledge portion  1806  of the second molded element  600 - 1 . The chamfer  2300  extends from a side of a cantilevered part of the tooth  1804  to a surface of the ledge portion  1806 . The chamfer  2300  decreases the amount of material that extends unsupported above the ledge portion  1806 , and thus increases the strength and/or stiffness of the tooth  1804 . Accordingly, the chamfer may prevent chipping or breaking of the tooth  1804  if the device  100  is dropped or otherwise subjected to potentially damaging forces. 
       FIG.  24    depicts a flow chart of a method  2400  of forming a housing for an electronic device, such as the housing  104 . At operation  2402 , a first molded element is formed between a first housing component and a second housing component (each forming a portion of the housing) to couple the first and second housing components. For example, first and second housing components may be introduced into a mold that holds the housing components such that they are separated by a gap. A first material (e.g., nylon, polyether ether ketone, etc.) may then be introduced into the mold such that the material flows into the gap and against first and second interlock features of the first and second housing components, respectively. The material may then be cured or otherwise hardened to form a rigid component comprising the first and second housing components joined by the first molded element. 
     The mechanical engagement between the first molded element and the interlock features couples the first molded element to the first and second housing components, and thus couples the first and second housing components to each other. Example interlock features are discussed herein. 
     At operation  2404 , an interlock feature is optionally formed in the first molded element. For example, a hole (e.g., a threaded hole or a tapered hole), recess, protrusion, or the like, may be formed in the first molded element after the first molded element is at least partially cured. The interlock feature may be formed by removing material (for example, by milling, grinding, drilling, threading, laser ablating, or the like) and/or by adding material (for example, by laser sintering, bonding, mechanical joining, or the like). 
     Alternatively or additionally, an interlock feature may be formed in the first molded element during molding of the first molded element. For example, the mold that holds the housing components may include protrusions, voids, or other features that will mold the interlock features into the first molded element when the first material is introduced into the mold. 
     At operation  2406 , a second molded element is formed. For example, the second molded element may be formed by introducing a second material (e.g., nylon, polyether ether ketone, etc.) into the gap after the first molded element is formed and at least partially cured. Optionally, an adhesive may be applied to the first molded element prior to forming the second molded element (e.g., prior to introducing the second material into the gap and against the first molded element), such that the second molded element is bonded to the first molded element by the adhesive. The second material may completely fill the gap such that the outer surface of the second molded element and the housing (e.g., portions of the housing that are next to the second molded element) form a substantially continuous surface (e.g., they may be coplanar). The second material may then be cured or otherwise hardened. 
     If the first molded element includes an interlock feature for engaging the second molded element, forming the second molded element may include flowing the second material against the interlock in the first molded element to mechanically engage the second molded element to the first molded element. 
     While any methods disclosed herein have been described and shown with reference to particular operations performed in a particular order, these operations may be combined, sub-divided, or re-ordered to form equivalent methods without departing from the teachings of the present disclosure. Accordingly, unless specifically indicated herein, the order and grouping of the operations is not a limitation of the present disclosure. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20230213
Publication Date: 20240827
Grant Date: 20240827
Priority Date: 20150904
Inventors: HILL, MATTHEW D.
WITTENBERG, MICHAEL B.
BUSTLE, SHANE
LE, DUY P.
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/1633", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C37/0082", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14467", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14311", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/3437", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F2200/1633", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0283", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/34", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/34", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1633", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C37/0082", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14467", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14311", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/3437", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F2200/1633", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3437", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/34", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C37/0082", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0283", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1633", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14467", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14311", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 58190436