PATENT DOCUMENT

Publication Number: US-9133559-B2
Application Number: US-201213414542-A
Country: US
Kind Code: B2

Title: Methods for forming electroplated aluminum structures

Abstract:
Anodized electroplated aluminum structures and methods for making the same are disclosed. Cosmetic structures according to embodiments of the invention are provided by electroplating a non-cosmetic structure with aluminum and then anodizing the electroplated aluminum. This produces cosmetic structures that may possess desired structural and cosmetic properties and that may be suitable for use as housing or support members of electronic devices.

Claims:
What is claimed is:  
     
       1. A method for providing a cosmetic coating on a support structure for an electronic device, the method comprising:
 depositing a qualification layer on a substrate surface of the support structure, the qualification layer configured to enhance bonding of a subsequently deposited aluminum layer, wherein depositing the qualification layer comprises:
 depositing a copper sub-layer of the qualification layer on the substrate surface of the support structure such that the copper sub-layer is continuously distributed along the substrate surface, and 
 depositing a nickel sub-layer of the qualification layer on the copper sub-layer, the nickel sub-layer having an optical brightness different than the copper sub-layer; 
 
 polishing a surface of the nickel sub-layer of the qualification layer; 
 electroplating the aluminum layer on the polished surface of the nickel sub-layer, the aluminum layer having at least a minimum thickness for accommodating a subsequent anodizing operation that consumes at least a portion of the aluminum layer, wherein electroplating the aluminum layer comprises:
 electroplating a first portion of the aluminum layer on the qualification layer using a first dopant, the first portion of the aluminum layer having a first grain structure, and 
 electroplating a second portion of the aluminum layer on the first portion of the aluminum layer using a second dopant different than the first dopant, the second portion having a second grain structure, the first grain structure different than the second grain structure; and 
 
 converting at least the portion of the aluminum layer to an aluminum oxide layer, wherein a top surface of the aluminum oxide layer corresponds to a top surface of the cosmetic coating. 
 
     
     
       2. The method of  claim 1 , wherein the optical brightness of the nickel sub-layer of the qualification layer imparts an optical quality to the cosmetic coating. 
     
     
       3. The method of  claim 2 , wherein the aluminum oxide layer is sufficiently clear such that the optical brightness of the nickel sub-layer of the qualification layer is viewable from a top surface of the cosmetic coating. 
     
     
       4. The method of  claim 2  wherein the qualification layer has substantially no gaps that expose the substrate surface of the support structure. 
     
     
       5. The method of  claim 1 , wherein the qualification layer has thickness ranging from about 5 micrometers to about 20 micrometers. 
     
     
       6. The method of  claim 1 , wherein electroplating the aluminum layer comprises depositing the aluminum layer to a thickness ranging from about 10 micrometers and about 75 micrometers. 
     
     
       7. The method of  claim 1 , wherein the support structure comprises metal and plastic surfaces. 
     
     
       8. The method of  claim 1 , wherein electroplating the aluminum layer comprises electroplating the aluminum layer to a thickness ranging from about 13 micrometers to about 120 micrometers. 
     
     
       9. A method for forming a protective coating on a support structure of an electronic device, the method comprising:
 applying a qualification layer on a surface of the support structure, the qualification layer configured to enhance bonding of a subsequently deposited aluminum layer; and 
 electroplating an aluminum layer on the qualification layer, wherein depositing the aluminum layer comprises:
 electroplating a first portion of the aluminum layer on the qualification layer using a first dopant, the first portion of the aluminum layer having a first grain structure, and 
 electroplating a second portion of the aluminum layer on the first portion of the aluminum layer using a second dopant different than the first dopant, the second portion having a second grain structure, the first grain structure different than the second grain structure, 
 wherein the first and second grain structures are associated with a hardness quality of the protective coating. 
 
 
     
     
       10. The method of  claim 9 , wherein applying the qualification layer comprises:
 depositing a first portion of a qualification layer on the surface of the support structure such that the first portion is continuously distributed along the surface, and 
 depositing a second portion of the qualification layer on the first portion, the second portion chosen to have an optical brightness. 
 
     
     
       11. The method of  claim 9 , further comprising: subsequent to electroplating the second portion of the aluminum layer, converting at least a portion of the second portion to an aluminum oxide layer. 
     
     
       12. The method of  claim 11 , further comprising: prior to converting the second portion to an aluminum oxide layer, processing the electroplated second portion to obtain a surface finish. 
     
     
       13. A method for forming a protective coating on an aluminum part of an electronic device, the method comprising:
 chemically removing a pre-existing oxide layer from a surface of the aluminum part; 
 electroplating a first aluminum layer on the chemically treated surface using a first dopant, the first aluminum layer having a first grain structure; and 
 electroplating a second aluminum layer on the first aluminum layer using a second dopant different than the first dopant, the second aluminum layer having a second grain structure, the first grain structure different than the second grain structure, 
 wherein the first and second grain structures are associated with a hardness quality of the protective coating. 
 
     
     
       14. The method of  claim 13 , wherein the first grain structure is larger than the second grain structure. 
     
     
       15. The method of  claim 13 , wherein the second grain structure is larger than the first grain structure. 
     
     
       16. The method of  claim 13 , further comprising:
 subsequent to electroplating the second aluminum layer, converting at least a portion of the second aluminum layer to an aluminum oxide layer. 
 
     
     
       17. The method of  claim 16 , further comprising converting at least a portion of the first aluminum layer to the aluminum oxide layer. 
     
     
       18. The method of  claim 13 , wherein chemically removing the pre-existing oxide layer is performed in a sealed environment substantially devoid of oxygen. 
     
     
       19. A method for forming a coating on a support structure of an electronic device, the method comprising:
 applying a qualification layer on a surface of the support structure, the qualification layer configured to enhance bonding of a subsequently deposited first aluminum layer; 
 electroplating the first aluminum layer on the qualification layer using a first dopant, the first aluminum layer having a first grain structure; and 
 electroplating a second aluminum layer on the first aluminum layer using a second dopant different than the first dopant, the second aluminum layer having a second grain structure, the first grain structure different than the second grain structure, 
 wherein the first and second grain structures are associated with a hardness quality of the coating. 
 
     
     
       20. The method of  claim 19 , wherein the qualification layer has an optical characteristic that imparts an optical quality to the coating. 
     
     
       21. The method of  claim 19 , wherein depositing the qualification layer comprises depositing a first qualification layer on the surface of the support structure and depositing a second qualification layer on the first qualification layer. 
     
     
       22. The method of  claim 19 , further comprising: processing the electroplated second aluminum layer to obtain a surface finish.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/449,855 filed Mar. 7, 2011, which is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     Electronic devices such as computers, cellphones, and portable media devices are often manufactured to exhibit desired cosmetic characteristics. In addition, such devices are manufactured with minimum structural requirements. It is desirable for certain materials used in such devices to exhibit sufficient structural integrity and cosmetic appeal. However, these two qualities can oppose each other depending on the material used. For example, a material may be aesthetically pleasing, but lack the desired structural properties, or alternatively, the material may be structurally sound, but does not exhibit desired cosmetics. 
     SUMMARY 
     Anodized electroplated aluminum structures and methods for making the same are disclosed. 
     In some embodiments, a cosmetic structure may include a non-cosmetic structure having a surface, a qualification layer disposed on the surface, and an electroplated aluminum layer disposed on the qualification layer. The electroplated aluminum layer may have an initial applied thickness ranging between 15 micrometers and 120 micrometers. The cosmetic structure may also include an aluminum anodized layer integrally formed with the electroplated aluminum layer. 
     In some embodiments, a method for making a cosmetic structure may include providing a non-cosmetic structure, preparing the non-cosmetic structure for an electroplating process, and electroplating the prepared non-cosmetic structure with aluminum to provide an electroplated aluminum structure. The electroplated aluminum layer may have an initial applied thickness ranging between 15 micrometers and 120 micrometers. The method may also include processing the electroplated aluminum structure to obtain a predetermined finish. A portion of the electroplated aluminum may be removed to provide the predetermined finish. The method may also include anodizing the processed electroplated aluminum structure having the predetermined finish to provide the cosmetic structure. 
     In some embodiments, an electronic device may include a display, a user interface, and a housing for securing the display and user interface. The housing may include a metal having an anodized electroplated aluminum cosmetic finish. 
     In some embodiments, a cosmetic structure may include a non-cosmetic structure, and an electroplated aluminum layer disposed on the non-cosmetic structure. The electroplated aluminum layer may include first and second dopants each having a different grain structure. The cosmetic structure may also include an aluminum anodized layer integrally formed with the electroplated aluminum layer. 
     In some embodiments, an article may include an aluminum structure, and an electroplated aluminum layer on the aluminum structure. An oxide layer of the aluminum structure may be removed. 
     In some embodiments, a method may include providing an aluminum structure, and, in a sealed environment, removing an oxide layer from the aluminum structure, and, after the removing, electroplating the aluminum structure to form an electroplated aluminum layer on the aluminum structure. 
     In some embodiments, an article may include a non-cosmetic structure. The non-cosmetic structure may include a first portion of a first material type, and a second portion of a second material type. The article may also include a first electroplated layer on the first portion, and a second electroplated layer on the second portion. 
     In some embodiments, a method may include providing a non-cosmetic structure. The non-cosmetic structure may include a first portion of a first material type, and a second portion of a second material type. The method may also include electroplating the non-cosmetic structure to form a first electroplated layer on the first portion and a second electroplated layer on the second portion. 
     In some embodiments, an article may include a non-cosmetic structure, a first electroplated layer on the non-cosmetic structure, a first anodized layer on the first electroplated layer, a second electroplated layer on the first anodized layer, and a second anodized layer on the second electroplated layer. 
     In some embodiments, a method may include providing a non-cosmetic structure, electroplating the non-cosmetic structure to form a first electroplated layer on the non-cosmetic structure, anodizing the first electroplated layer to form a first anodized layer on the first electroplated layer, processing the anodized electroplated structure to remove a portion of the anodized electroplated structure, electroplating the processed anodized electroplated structure to form a second electroplated layer, and anodizing the second electroplated layer to form a second anodized layer on the second electroplated layer. 
     In some embodiments, a method may include providing a non-cosmetic structure, processing a portion of the non-cosmetic structure, and electroplating the non-cosmetic structure to form an electroplated layer on an unprocessed portion of the non-cosmetic structure. The processing may include at least one of masking and laminating the portion. After the electroplating, the method may include surface finishing the electroplated layer. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects and advantages of the invention will become more apparent upon consideration of the following detailed description, taken in conjunction with accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1  shows an illustrative non-cosmetic structure that may receive a cosmetic finish in accordance with an embodiment of the invention; 
         FIG. 2  shows an illustrative cross-sectional view of such a cosmetic structure in accordance with an embodiment of the invention; 
         FIG. 3  shows an illustrative process for manufacturing a cosmetic structure having an anodized electroplated aluminum surface according to an embodiment of the invention; 
         FIG. 4  shows an illustrative cross-sectional view of a cosmetic structure with aluminum plated on an aluminum structure in accordance with an embodiment of the invention; 
         FIG. 5  shows an illustrative process for manufacturing a cosmetic structure having an anodized electroplated aluminum surface on an aluminum structure in accordance with an embodiment of the invention; 
         FIG. 6  shows an illustrative cross-sectional view of a surface of at least one of an electroplated layer and an anodized layer of a cosmetic structure in accordance with an embodiment of the invention; 
         FIG. 6A  shows an illustrative cross-sectional view of a surface of at least one of an electroplated layer and an anodized layer of a cosmetic structure having a particular grains structure in accordance with an embodiment of the invention; 
         FIG. 6B  shows an illustrative cross-sectional view of a surface of at least one of an electroplated layer and an anodized layer of a cosmetic structure having a particular grains structure in accordance with an embodiment of the invention; 
         FIG. 6C  shows an illustrative cross-sectional view of a surface of at least one of an electroplated layer and an anodized layer of a cosmetic structure having a particular grains structure in accordance with an embodiment of the invention; 
         FIG. 6D  shows an illustrative cross-sectional view of a surface of at least one of an electroplated layer and an anodized layer of a cosmetic structure having a particular grains structure in accordance with an embodiment of the invention; 
         FIG. 7  shows an illustrative cross-sectional view of a selectively electroplated cosmetic structure in accordance with an embodiment of the invention; 
         FIG. 8  shows an illustrative process for manufacturing a cosmetic structure by selective electroplating according to an embodiment of the invention; 
         FIG. 9  shows an illustrative cross-sectional view of a cosmetic structure including multiple substrates in accordance with an embodiment of the invention; 
         FIG. 10  shows an illustrative process for manufacturing a cosmetic structure including multiple substrates according to an embodiment of the invention; 
         FIG. 11  shows an illustrative cross-sectional view of a double anodized cosmetic structure in accordance with an embodiment of the invention; 
         FIG. 12  shows an illustrative process for manufacturing a cosmetic structure by double anodization according to an embodiment of the invention; and 
         FIG. 13  shows an illustrative process for manufacturing a cosmetic structure with an electroplated aluminum layer having a minimum thickness according to an embodiment of the invention; and 
         FIG. 14  is a schematic view of an illustrative electronic device in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Cosmetic structures according to embodiments of the invention are provided by electroplating a non-cosmetic structure and then anodizing the electroplated structure. This can, for example, produce cosmetic structures that possess desired structural and cosmetic properties and that are suitable for use as housing or support members of electronic devices. 
       FIG. 1  shows an illustrative non-cosmetic structure  100  that may receive a cosmetic finish in accordance with an embodiment of the invention. 
     Structure  100  may have any suitable size and shape. For example, structure  100  can have curved surfaces, planar surfaces, edges, cutouts, recesses, cavities, through-holes, threaded holes or cavities, or any combination thereof. As illustrated in  FIG. 1 , structure  100  can have a combination of curved and planar surfaces, and one or more through-holes. 
     In some embodiments, structure  100  may be used as a part of an electronic device such as, for example, a portable media player, a smart phone, a laptop computer, or a tablet. Structure  100  may provide structural support for the electronic device and may also be visible to a user. Structural support may be provided in the form of a cover, such as a backplate, or in the form of a frame (e.g., a shell of a laptop body). Because portions of structure  100  may be visible to the user, a cosmetic finish can be applied in accordance with embodiments of this invention. 
     Structure  100  can be constructed from any suitable material. For example, structure  100  can be constructed from steel or a steel alloy, magnesium, aluminum or an aluminum alloy, or titanium. Each of these metals in their raw and untreated state, however, do not provide the combination of durability and desired cosmetic appearance. Steel, for example, can be polished to exhibit a shiny mirror-like finish, but is susceptible to scratches, which dull the finish, and readily retains oil left behind by fingerprints. Both magnesium and aluminum exhibit undesired cosmetic appearance—that is, they both have a dull finish. 
     As another example, structure  100  can be constructed from a polymer, a glass embedded plastic, or materials such as ceramic, nylon, carbon fiber, or any combination of two or more of the foregoing. As yet another example, structure  100  can be constructed to include both a metal (e.g., steel, magnesium, or aluminum) and a plastic material. The plastic material may provide a “window” suitable for passage of RF signals. Further, structure  100  may include an assembly or a single part. 
     Non-cosmetic structures such as structure  100  may be subjected to a cosmetic finishing process according to embodiments of the invention to provide a cosmetic structure.  FIG. 2  shows an illustrative cross-sectional view of such a cosmetic structure. As shown, cosmetic structure  200  can include non-cosmetic structure  210 , qualification layer  220 , electroplated aluminum layer  230 , and aluminum anodized layer  240 . The thickness of each layer is illustrative and it is understood that the thickness of each layer may vary. In addition, the thickness of structure  210  can also vary. 
     Non-cosmetic structure  210  can include any suitable structure such as that described above in connection with structure  100  of  FIG. 1 . If non-cosmetic structure  210  includes an edge, through-hole, cavity, threaded hole, or any other feature or combination thereof, each of layers  220 ,  230 , and  240  can exist on each those features. This can ensure that each feature of non-cosmetic structure  210  has a desired cosmetic finish, which provides aesthetics and functional properties. 
     Qualification layer  220  can include one or more materials that prepare non-cosmetic structure  210  for an aluminum electroplating process. For example, qualification layer  220  can include a nickel layer. As another example, qualification layer  220  can include a copper layer and a nickel layer, which may be deposited on top of the copper layer. Layer  220  may be applied to structure  210  using any suitable process, including, for example, an immersion bath, electroplating, electroless plating, sputtering, or physical vapor deposition (PVD). 
     Qualification layer  220  can serve as a bonding surface for electroplated aluminum layer  230 , and as such layer  230  can follow the contours and placement of layer  220 . Because layer  230  may mimic placement of layer  220 , it is desirable for layer  230  to be deposited on non-cosmetic structure  210  such that it forms a uniform coating of a predetermined thickness. The thickness may range between 5 um and 20 um, and in some embodiments may be about 10 um. Although it is desirable to have a uniform thickness, it is understood that the thickness of layer  220  may vary throughout. For example, layer  220  may vary in thickness by a few microns. In addition, it is further understood that the thickness of layer  220  may vary (e.g., from 10 um to 20 um) depending on the feature being coated. For example, the thickness of layer  220  on a relatively large planer surface may be greater than the thickness of layer  220  on a cavity or threaded insert. 
     The uniformity of the coating of layer  220  may be such that no or substantially no gaps or pores exist that will expose non-cosmetic structure  210 . A uniform coating of layer  220  can ensure that electroplated aluminum layer  230  is continuously distributed across structure  210 . 
     Electroplated aluminum layer  230  is a layer of aluminum or alloy thereof that is electroplated on top of qualification layer  220 . Electroplating is a plating process in which metal ions in a solution are moved by an electric field to coat an electrode. The solution may include an electrolytic bath of toluene or ionic liquid from which an aluminum salt can be reduced. The electrode may be the combination of structure  210  and layer  220 . The process can be regulated by controlling a variety of parameters, including voltage, amperage, temperature, dwell time, and purity of solution. It should be appreciated that parameters of the electroplating process may be adjusted depending on physical characteristics (e.g., shape) of structure  210 . For example, layer  230  may be thicker at edges of structure  210 . As another example, curved portions of structure  210  may be plated with aluminum or aluminum alloy in a manner that compensates for the curves. 
     Aluminum electroplated layer  230  can have any suitable thickness. For example, the thickness of layer  230  can vary between 10 and 120 microns, between 10 um and 75 um, 18 um and 25 um. In some embodiments, the thickness can be 10 microns, 18 microns, 33 microns, 50 microns, or 75 microns. It may be desirable that layer  230  not exceed a maximum thickness to prevent variability in the surface. It may also be desirable for layer  230  to have at least a minimum thickness to accommodate a processing step that removes a portion of layer  230  before it is anodized and to ensure structural reliability of layer  230 . The processing step may remove any suitable amount of layer  230  to achieve desired results (e.g., a matte or mirror surface). The processing step may blast away or etch away a portion of layer  230  to provide a matte surface. It should be appreciated that parameters of the surface finishing process may be adjusted depending on physical characteristics (e.g., shape) of structure  210 . For example, an amount of layer  230  being removed from a planar surface may be different from an amount of layer  230  being removed from sharp curves or edges. In addition, or alternatively, the processing step can lathe or polish away a portion of layer  230  to provide a mirror finish. 
     In some embodiments, a minimum thickness of 10 um of layer  230  may be too thin to polish, but may be suitable for obtaining a textured or matte finish. As another example, a minimum thickness of 18 um of layer  230  may be required to achieve a mirror finish. It should be appreciated that the minimum thickness of layer  230  required for achieving any of the textured or mirror finish may depend on the material selected in structure  210 . For example, the thickness of the electroplated aluminum layer may be based on a stiffness of the non-cosmetic structure. As another example, a glass substrate may require a thicker layer  230  than a steel substrate in order to prevent cracking. 
     Electroplating with aluminum, rather than with other materials, can provide certain benefits for a finished part, including, but not limited to, cosmetic appeal, desired thermal qualities, structural reliability, and flexibility during manufacturing, and corrosion resistance. In addition, the soft property of aluminum can be leveraged during manufacturing (e.g., laser marking/etching and/or machining can be performed on an aluminum plated part), work hardened materials can be plated with aluminum, and a non-cosmetic part may even be colored first prior to being plated with aluminum. 
     Anodized aluminum layer  240  may be a layer wherein a surface portion of electroplated aluminum layer  230  is anodized. Anodizing can increase corrosion resistance and surface hardness (e.g., to prevent scratching) of aluminum layer  230 . In addition, anodizing can permit coloring of aluminum layer  230 . Anodized aluminum layer  240  can have any suitable thickness. In some embodiments, layer  230  can be anodized via direct electrical current (DC) or via pulses of current (e.g., pulse anodization), where layer  230  may be bathed (e.g., in sulfuric acid) to convert at least a portion of the surface of layer  230  into aluminum oxide. In some embodiments, the thickness of the aluminum oxide layer may be 35 microns or less. For example, the thickness can be about 10 microns. In other embodiments, the thickness can range between 5 and 35 microns, 10 and 30 microns, and 10 and 20 microns. Therefore, layer  230  may need to have an initial thickness greater than the desired thickness of layer  240 , so that sufficient electroplated aluminum is available for conversion. 
     It should also be appreciated that, because the anodization process may result in a cloudy aluminum oxide layer, steps can be taken to improve the clarity thereof. 
     For example, if pulse anodization is employed, the pulses of current can be adjusted to achieve improved clarity. In addition, additional processing steps (e.g., polishing and texturing) may be also applied to layer  240 . 
       FIG. 3  shows an illustrative process  300  for manufacturing a cosmetic structure having an anodized electroplated aluminum surface according to an embodiment of the invention. Beginning at step  310 , a non-cosmetic structure (e.g., non-cosmetic structure  210 ) can be provided. The non-cosmetic structure can be any suitable shape or construction and can be constructed from a metal, a plastic, or combination thereof. See discussion of structure  100  above for additional details for suitable non-cosmetic structures. 
     At step  320 , the non-cosmetic structure may be processed or prepared for an electroplating step. In some embodiments, certain parts or portions of the non-cosmetic structure can be masked so that the masked portion will not be cosmetically finished. The non-cosmetic structure may be prepared by being cleaned (e.g., to remove impurities, grease, or any oxidation buildup). The non-cosmetic structure can also be prepared by receiving a qualification layer. If desired, the non-cosmetic structure can be polished or textured prior to or after the cleaning step. The qualification layer, as discussed above in connection with  FIG. 2 , may include a nickel layer or a copper layer that is then covered by a nickel layer. For example, the nickel layer may have a particular optical characteristic (e.g., a particular brightness). As also discussed above, qualification layer may uniformly coat all desired features of the non-cosmetic structure. If desired, the qualification layer can also be polished, textured, or subjected to one or more rinse solvents. In some embodiments, the qualification layer may further be masked with any suitable material. 
     At step  330 , the processed non-cosmetic structure may be electroplated with aluminum. In some embodiments, the electroplating step may include the use of toluene, ionic liquid, aluminum sulphite/sulphate, and/or any other suitable material. After an electroplated aluminum layer of desired thickness is deposited onto the non-cosmetic structure, the process may proceed to step  340 . At step  340 , the electroplated aluminum layer may be processed to attain a desired finish. Depending on how the electroplated aluminum layer is processed, it can exhibit, for example, a mirror-like finish or a matte finish. 
     In some embodiments, the electroplated aluminum layer may first be textured by a blasting and/or an etching process (e.g., laser etching), and subsequently surface finished. Surface finishing may, for example, involve localized processing of the electroplated aluminum layer using a targeted or targeting process. Any of a blast process, etching (e.g., laser etching), a physical mask, and/or any other suitable finishing process may be applied as part of surface finishing the electroplated aluminum layer. 
     At step  350 , the processed electroplated aluminum structure may be anodized. The anodizing step can optionally include any of dye coloring and sealing. Sealing may include the use of any suitable material that may allow for the anodized layer to be further electroplated and/or anodized, if desired. In embodiments that include dye coloring and sealing, for example, a subsequent surface finish may also be performed on any visible or non-visible portion of the anodized electroplated aluminum layer. Such surface finishing of the anodized layer may, for example, include polishing, etching (e.g., of graphics and/or of artwork), engraving, CNC milling, and/or drilling microperforations therein. Following step  350 , an anodized electroplated aluminum structure with appealing cosmetics and functional properties may be provided, and any other components may be attached to the cosmetic structure to form at least a part of an assembly. 
     One or more of the steps  310 ,  320 ,  330 ,  340 , and  350  may be performed by automated machinery in a controlled environment devoid of oxygen. For example, the steps may be performed in a nitrogen only atmosphere. It is understood that additional steps may be added without departing from the spirit of the invention. For example, a cleaning step may be added after the completion of step  330 . As another example, an additional aluminum coating step may be used to coat the non-cosmetic structure with aluminum. The additional aluminum coating step may be implemented by physical vapor deposition, thermal spray, or cold spray. This coating step may be applied before or after the electroplating step. 
     In some embodiments, an aluminum or aluminum alloy substrate or structure can be electroplated with aluminum or aluminum alloy.  FIG. 4  shows an illustrative cross-sectional view of a cosmetic structure with aluminum plated on an aluminum structure in accordance with an embodiment of the invention. Similar to cosmetic structure  200  of  FIG. 2 , cosmetic structure  400  can include non-cosmetic aluminum structure  410 , electroplated aluminum layer  420 , and anodized layer  430 . However, cosmetic structure  400  may lack a qualification layer (e.g., layer  220  of  FIG. 2 ). In some embodiments, to overcome potential difficulties in achieving aluminum plating on an aluminum substrate, an existing oxide layer on the aluminum substrate may first be removed (e.g., preferably in a sealed environment devoid of oxygen) prior to plating the aluminum structure with aluminum. With an existing oxide layer removed, aluminum may then be electroplated much more easily onto the aluminum structure. This can result in decreased manufacturing costs (e.g., a qualification layer is no longer required) and can maintain structural integrity of a finished cosmetic structure (e.g., any corrosion of a qualification layer can be avoided). 
       FIG. 5  shows an illustrative process for manufacturing a cosmetic structure having an anodized electroplated aluminum surface on an aluminum structure. Process  500  may begin at step  502 . At step  504 , a non-cosmetic aluminum structure (e.g., structure  410 ) may be provided. 
     At step  506 , an existing oxide layer (not shown) on the non-cosmetic aluminum structure may be removed. Any suitable chemical process may be applied to the surface of the non-cosmetic aluminum structure, for example, to remove any oxide layer that may be present. At step  508 , after the oxide layer is removed from the non-cosmetic aluminum structure, the non-cosmetic aluminum structure may be electroplated with aluminum. As discussed above in connection with  FIG. 2 , it should be appreciated that any parameters of the electroplating process (e.g., voltage, current, temperature, and dwell time) can be controlled to produce a desired thickness and quality of the electroplated aluminum layer. In some embodiments, a finishing process can be performed immediately after step  508  to attain a desired finish for the electroplated aluminum layer (e.g., layer  420 ). For example, depending on how the electroplated aluminum layer is processed, it can exhibit a mirror like finish or a matte finish. 
     Though not shown, after step  508 , the electroplated aluminum structure may be anodized. In some embodiments, a dye coloring process can be performed during the anodizing in order to achieve a coloring effect. Following the anodizing, a cosmetic structure having an anodized electroplated aluminum surface on an aluminum structure may be provided. 
     In some embodiments, the hardness of an electroplated layer (e.g., layer  420 ) can be controlled. For example, electroplating of a non-cosmetic structure may include immersing the non-cosmetic structure in a first bath of aluminum or aluminum alloy solution having a particular grain structure (or size), and subsequently immersing the electroplated non-cosmetic structure in a second bath of aluminum or aluminum alloy solution having a different grain structure (or size). As another example, the non-cosmetic structure may be immersed in a bath of aluminum or aluminum alloy solution having a mixed grain structure (or mixed grain sizes). In particular, the mixed grain structure (or sizes) may be produced by mixing a first aluminum or aluminum alloy solution having a particular grain structure (or size) with a second solution (e.g., of aluminum or of any other suitable type of element) having a different grain structure (or size). In this manner, one or more properties of an electroplated layer&#39;s surface can be modified (e.g., chemically) to provide a desired structural integrity. In some embodiments, the aluminum or aluminum alloy solution to be electroplated may be modified with one or more dopants to produce a hardness quality of grains. It should be appreciated that any suitable type of material may be used to dope the aluminum or aluminum alloy solution, as long as a resulting electroplated layer exhibits a desired hardness quality. In some embodiments, 99.99% pure aluminum may be used for the electroplating, which may allow for better control of the thickness of the grain structure. For example, various aluminum and dopant baths may be mixed in any suitable manner and used in electroplating to control the thickness of the grain structure of a resulting electroplated layer.  FIG. 6  shows an illustrative cross-sectional view  600  of a surface of at least one of an electroplated layer of a cosmetic structure in accordance with an embodiment of the invention. Layer  610  can include surface  620 , which can include a pattern of grains  630  that at least partially defines a structural characteristic of layer  610 . 
       FIG. 6A  shows an illustrative cross-sectional view of a surface of at least one of an electroplated layer and an anodized layer of a cosmetic structure having a particular grains structure in accordance with an embodiment of the invention. Surface  620   a  of cosmetic structure  600   a  can include a pattern of grains  630   a  having a relatively large or rough grain structure.  FIG. 6B  shows an illustrative cross-sectional view of a surface of at least one of an electroplated layer and an anodized layer of a cosmetic structure having a particular grains structure in accordance with an embodiment of the invention. Surface  620   b  of cosmetic structure  600   b  can include a pattern of grains  630   b  having a relatively small or fine grain structure, in contrast to pattern of grains  630   a.    
     In some embodiments, the electroplated layer and/or the anodized layer may be controlled to include layered patterns of grains each having relatively different grain structures.  FIG. 6C  shows an illustrative cross-sectional view of a surface of at least one of an electroplated layer and an anodized layer of a cosmetic structure having a particular grains structure in accordance with an embodiment of the invention. Surface  620   c  of cosmetic structure  600   c  can include a lower pattern of grains  630   c  having a relatively large or rough grain structure and an upper pattern of grains  632   c  having a relatively small or fine grain structure.  FIG. 6D  shows an illustrative cross-sectional view of a surface of at least one of an electroplated layer and an anodized layer of a cosmetic structure having a particular grains structure in accordance with an embodiment of the invention. Surface  620   d  of cosmetic structure  600   d  can include a lower pattern of grains  630   d  having a relatively small or fine grain structure and an upper pattern of grains  632   d  having a relatively large or rough grain structure, in contrast to layer  610 . 
     In some embodiments, a non-cosmetic structure may be selectively electroplated to provide a selectively plated cosmetic structure. This can yield a desired cosmetic appearance on select portions of a non-cosmetic structure.  FIG. 7  shows an illustrative cross-sectional view of a selectively electroplated cosmetic structure in accordance with an embodiment of the invention. Cosmetic structure  700  may include non-cosmetic structure  710 , non-plated portions  720 , electroplated portion  730 , and electroplated layer  740 . Though not shown, in some embodiments, cosmetic structure  700  may also include a qualification layer similar to layer  220  of cosmetic structure  200 . In addition, it should be appreciated that cosmetic structure  700  may further include an anodized layer (e.g., similar to layer  240  of  FIG. 2 ). 
       FIG. 8  shows an illustrative process for manufacturing a cosmetic structure by selective electroplating according to an embodiment of the invention. Process  800  may begin at step  802 . At step  804 , a non-cosmetic structure (e.g., structure  710 ) may be provided. At step  806 , portions of the non-cosmetic structure that are not to be electroplated (e.g., non-plated portions  720 ) may be masked or laminated. It should be appreciated that masking or lamination of the non-cosmetic structure may be achieved using any suitable type of material. At step  808 , the masked or laminated non-cosmetic structure may be electroplated (e.g., with aluminum or any suitable type of material). With portions of the non-cosmetic structure being masked or laminated, only uncovered portion(s) (e.g., electroplated portion  730 ) of the structure may be electroplated at step  808 . Though not shown, the mask or laminating material may be removed at any time after electroplating is complete of the uncovered portion(s) is complete. 
     In some embodiments, a non-cosmetic structure may include two or more types of material, where a different finish on each type of material may be desired.  FIG. 9  shows an illustrative cross-sectional view of a cosmetic structure including multiple substrates in accordance with an embodiment of the invention. Cosmetic structure  900  may include non-cosmetic structure  910 , which may be constructed of structural portions  920  of one material type (e.g., aluminum) and a structural portion  930  of another material type (e.g., ceramic), and electroplated layer  940 . Electroplated layer  940  may include first finished portions  950  overlaid on structural portions  920 , and a second finished portion  960  overlaid on structural portion  930 . Though not shown, in some embodiments, cosmetic structure  900  may also include a qualification layer similar to layer  220  of cosmetic structure  200 . 
       FIG. 10  shows an illustrative process for manufacturing a cosmetic structure including multiple substrates according to an embodiment of the invention. Process  1000  may begin at step  1002 . At step  1004 , a non-cosmetic structure (e.g., non-cosmetic structure  910 ) may be provided. The non-cosmetic structure may include one or more structural portions of one material type (e.g., structural portions  920 ) and one or more portions of another material type (e.g., structural portion  930 ). 
     At step  1006 , the non-cosmetic structure may be electroplated to form an electroplated layer. Depending on properties of the non-cosmetic structure that is directly beneath the electroplated layer, one portion of the electroplated layer may have properties that are different from those of another portion of the electroplated layer. In some embodiments, after step  1006 , the electroplated layer may be surface finished. Due to the different material properties of the different portions of the non-cosmetic structure, a characteristic of one or more portions of an electroplated layer (e.g., first finished portions  950 ) that is deposited on the one or more structural portions of one material type (e.g., structural portions  920 ) may be different from a characteristic of one or more portions of the electroplated layer (e.g., second finished portion  960 ) that is deposited on the one or more of the structural portions of another material type (e.g., structural portion  930 ). For example, if the non-cosmetic structure includes one or more aluminum portions and one or more ceramic portions, surface finishing an electroplated layer may result in a portion of the electroplated layer deposited on the aluminum portions to exhibit a matte finish, and a portion of the electroplated layer deposited on the ceramic portions to exhibit a clear finish. 
     In some embodiments, a non-cosmetic structure may be plated and anodized more than once (e.g., two times) to provide a finished cosmetic structure that may include a desired pattern of surface texture and/or colors. For example, a non-cosmetic structure may be electroplated (e.g., with aluminum) to form a first electroplated layer. The first electroplated layer may then be anodized to form a first anodized layer over the first electroplated layer, and a portion of the first electroplated layer and a portion of the first anodized layer may each be removed. As a result, a recess may be created between remaining portions of the first electroplated layer and the first anodized layer, and a second electroplated layer may be formed in the recess. A second anodized layer may then be formed over the second electroplated layer, resulting in a double anodized cosmetic structure. Such a double anodization process may eliminate any need to mask portions of the non-cosmetic structure during manufacturing.  FIG. 11  shows an illustrative cross-sectional view of a double anodized cosmetic structure in accordance with an embodiment of the invention. Cosmetic structure  1100  may include non-cosmetic structure  1110 , first electroplated layer portions  1120  (e.g., of aluminum), first anodized layer portions  1130 , second electroplated layer portion  1150 , and second anodized layer portion  1160 . Though not shown, in some embodiments, cosmetic structure  1100  may also include one or more qualification layers similar to layer  220  of cosmetic structure  200 . Though cosmetic structure  1100  is shown to have a particular pattern of electroplated and anodized layers, it should be appreciated that any suitable design or pattern of each of these layers may be achieved with double anodization. 
       FIG. 12  shows an illustrative process for manufacturing a cosmetic structure by double anodization according to an embodiment of the invention. Process  1200  may begin at step  1202 . At step  1204 , a non-cosmetic structure (e.g., non-cosmetic structure  1110 ) may be provided. 
     At step  1206 , the non-cosmetic structure may be electroplated (e.g., with aluminum) to form an electroplated layer (e.g., including first electroplated layer portions  1120  and one or more other first electroplated layer portions that are not shown). In some embodiments, a finishing process can be performed immediately after step  1206  to attain a desired finish of the electroplated layer. For example, depending on how the electroplated aluminum layer is processed, it can exhibit a mirror like finish or a matte finish. 
     At step  1208 , the electroplated structure may be anodized to form an anodized layer (e.g., first anodized layer portions  1130  and one or more other first anodized layer portions that are not shown). In some embodiments, a dye coloring process can be performed during anodizing step  1208  in order to achieve a coloring effect. 
     At step  1210 , the anodized electroplated structure may be processed to remove a portion of the anodized electroplated structure. As a result, what remains of the anodized electroplated structure may function as a mask for use during further steps of the manufacturing of the cosmetic structure. The modification can include, for example, cutting (e.g., via laser etching) one or more portions of the first anodized layer (e.g., first anodized layer portions (not shown) other than first anodized layer portions  1130 ) and electroplated layer (e.g., first electroplated layer portions (not shown) other than first electroplated layer portions  1120 ) to create one or more recesses (not shown, but may be at least partially occupied by second electroplated layer portion  1150  and second anodized layer portion  1160 ). 
     At step  1212 , the modified anodized electroplated structure may be further electroplated to form one or more second electroplated layers (e.g. electroplated layer portion  1150 ). This second electroplated layer may be processed to attain a desired finish. At step  1214 , a second anodization process may be performed on the second electroplated structure. Anodizing step  1214  may optionally include dye coloring. Following step  1214 , a double anodized electroplated structure with appealing cosmetics and functional properties may be provided. 
     In some embodiments, a dye coloring process performed during the first anodizing step  1206  may employ a dye color different from that employed in a dye coloring process performed during the second anodizing step  1212 . It should be appreciated that step  1210  can be performed at any time after step  1206  (e.g., prior to surface finishing the electroplated layer). Further, the first electroplated layer may be formed from a material that is different from a material that forms the second electroplated layer. For example, the first electroplated layer may be formed from aluminum, whereas the second electroplated layer may be formed from nickel. 
       FIG. 13  shows an illustrative process for manufacturing a cosmetic structure with an electroplated aluminum layer having a minimum thickness according to an embodiment of the invention. Process  1300  may begin at step  1302 . At step  1304 , a non-cosmetic structure (e.g., non-cosmetic structure  210 ) may be provided. 
     At step  1306 , the non-cosmetic structure may be electroplated with aluminum. As discussed above in connection with  FIG. 2 , it may be desirable for an electroplated aluminum layer to have a minimum thickness to accommodate a processing step that removes a portion of the electroplated aluminum layer before it is anodized and to ensure structural reliability. Thus, the electroplating of step  1306  may include electroplating the non-cosmetic structure such that the electroplated aluminum layer has a minimum thickness. As discussed above in connection with  FIG. 2 , it should be appreciated that the minimum thickness of the electroplated aluminum layer required for achieving any of the textured or mirror finish may depend on a type of material of the non-cosmetic structure. For example, the thickness of the electroplated aluminum layer may be based on a stiffness of the non-cosmetic structure. As another example, a glass substrate may require a thicker layer  230  than a steel substrate in order to prevent cracking. 
     At step  1308 , the electroplated aluminum layer may be surface finished. For example, a minimum thickness of 10 um of the electroplated aluminum layer may be too thin to polish, but may be required in order to achieve a textured finish. As another example, a minimum thickness of 18 um of layer  230  may be required to achieve a mirror finish. At step  1310 , the surface finished electroplated aluminum layer may be anodized. In some embodiments, a dye coloring process can be performed during anodizing step  1310  in order to achieve a coloring effect. 
     Though not shown, in some embodiments, the electroplated aluminum layer can be deposited onto the non-cosmetic structure in separate layers. For example, to control the thickness of the electroplated aluminum layer, a rough electroplated aluminum layer and a fine electroplated aluminum layer may separately be deposited. The rough electroplated aluminum layer may first be applied onto the non-cosmetic structure to serve as a base layer of aluminum, where the fine electroplated aluminum layer may be subsequently applied on the rough layer. In some embodiments, the fine layer, rather than the rough layer, may first be applied onto the non-cosmetic structure. 
       FIG. 14  is a schematic view of an illustrative electronic device  1400  for displaying visible information to a user. Electronic device  1400  may be any portable, mobile, or hand-held electronic device configured to present visible information on a display assembly wherever the user travels. Alternatively, electronic device  1400  may not be portable at all, but may instead be generally stationary. Electronic device  1400  can include, but is not limited to, a music player, video player, still image player, game player, other media player, music recorder, movie or video camera or recorder, still camera, other media recorder, radio, medical equipment, domestic appliance, transportation vehicle instrument, musical instrument, calculator, cellular telephone, other wireless communication device, personal digital assistant, remote control, pager, computer (e.g., desktop, laptop, tablet, server, etc.), monitor, television, stereo equipment, set up box, set-top box, boom box, modem, router, keyboard, mouse, speaker, printer, and combinations thereof. In some embodiments, electronic device  1400  may perform a single function (e.g., a device dedicated to displaying image content) and, in other embodiments, electronic device  1400  may perform multiple functions (e.g., a device that displays image content, plays music, and receives and transmits telephone calls). 
     Electronic device  1400  may include a housing  1401 , a processor or control circuitry  1402 , memory  1404 , communications circuitry  1406 , power supply  1408 , input component  1410 , and display assembly  1412 . Electronic device  1400  may also include a bus  1403  that may provide a data transfer path for transferring data and/or power, to, from, or between various other components of device  1400 . In some embodiments, one or more components of electronic device  1400  may be combined or omitted. Moreover, electronic device  1400  may include other components not combined or included in  FIG. 14 . For the sake of simplicity, only one of each of the components is shown in  FIG. 1 . 
     Memory  1404  may include one or more storage mediums, including for example, a hard-drive, flash memory, permanent memory such as read-only memory (“ROM”), semi-permanent memory such as random access memory (“RAM”), any other suitable type of storage component, or any combination thereof. Memory  1404  may include cache memory, which may be one or more different types of memory used for temporarily storing data for electronic device applications. Memory  1404  may store media data (e.g., music, image, and video files), software (e.g., for implementing functions on device  1400 ), firmware, preference information (e.g., media playback preferences), lifestyle information (e.g., food preferences), exercise information (e.g., information obtained by exercise monitoring equipment), transaction information (e.g., information such as credit card information), wireless connection information (e.g., information that may enable device  1400  to establish a wireless connection), subscription information (e.g., information that keeps track of podcasts or television shows or other media a user subscribes to), contact information (e.g., telephone numbers and e-mail addresses), calendar information, any other suitable data, or any combination thereof. 
     Communications circuitry  1406  may be provided to allow device  1400  to communicate with one or more other electronic devices or servers using any suitable communications protocol. For example, communications circuitry  1406  may support Wi-Fi™ (e.g., an 802.11 protocol), Ethernet, Bluetooth™, high frequency systems (e.g., 900 MHz, 2.4 GHz, and 5.6 GHz communication systems), infrared, transmission control protocol/internet protocol (“TCP/IP”) (e.g., any of the protocols used in each of the TCP/IP layers), hypertext transfer protocol (“HTTP”), BitTorrent™, file transfer protocol (“FTP”), real-time transport protocol (“RTP”), real-time streaming protocol (“RTSP”), secure shell protocol (“SSH”), any other communications protocol, or any combination thereof. Communications circuitry  1406  may also include circuitry that can enable device  1400  to be electrically coupled to another device (e.g., a computer or an accessory device) and communicate with that other device, either wirelessly or via a wired connection. 
     Power supply  1408  may provide power to one or more of the components of device  1400 . In some embodiments, power supply  1408  can be coupled to a power grid (e.g., when device  1400  is not a portable device, such as a desktop computer). In some embodiments, power supply  1408  can include one or more batteries for providing power (e.g., when device  1400  is a portable device, such as a cellular telephone). As another example, power supply  1408  can be configured to generate power from a natural source (e.g., solar power using one or more solar cells). 
     One or more input components  1410  may be provided to permit a user to interact or interface with device  1400 . For example, input component  1410  can take a variety of forms, including, but not limited to, a track pad, dial, click wheel, scroll wheel, touch screen, one or more buttons (e.g., a keyboard), mouse, joy stick, track ball, and combinations thereof. For example, input component  1410  may include a multi-touch screen. Each input component  1410  can be configured to provide one or more dedicated control functions for making selections or issuing commands associated with operating device  1400 . 
     Electronic device  1400  may also include one or more output components that may present information (e.g., textual, graphical, audible, and/or tactile information) to a user of device  1400 . An output component of electronic device  1400  may take various forms, including, but not limited, to audio speakers, headphones, audio line-outs, visual displays, antennas, infrared ports, rumblers, vibrators, or combinations thereof. 
     For example, electronic device  1400  may include display assembly  1412  as an output component. Display  1412  may include any suitable type of display or interface for presenting visible information to a user of device  1400 . In some embodiments, display  1412  may include a display embedded in device  1400  or coupled to device  1400  (e.g., a removable display). Display  1412  may include, for example, a liquid crystal display (“LCD”), a light emitting diode (“LED”) display, an organic light-emitting diode (“OLED”) display, a surface-conduction electron-emitter display (“SED”), a carbon nanotube display, a nanocrystal display, any other suitable type of display, or combination thereof. Alternatively, display  1412  can include a movable display or a projecting system for providing a display of content on a surface remote from electronic device  1400 , such as, for example, a video projector, a head-up display, or a three-dimensional (e.g., holographic) display. As another example, display  1412  may include a digital or mechanical viewfinder. In some embodiments, display  1412  may include a viewfinder of the type found in compact digital cameras, reflex cameras, or any other suitable still or video camera. 
     It should be noted that one or more input components and one or more output components may sometimes be referred to collectively as an I/O interface (e.g., input component  1410  and display  1412  as I/O interface  1411 ). It should also be noted that input component  1410  and display  1412  may sometimes be a single I/O component, such as a touch screen that may receive input information through a user&#39;s touch of a display screen and that may also provide visual information to a user via that same display screen. 
     Processor  1402  of device  1400  may control the operation of many functions and other circuitry provided by device  1400 . For example, processor  1402  may receive input signals from input component  1410  and/or drive output signals to display assembly  1412 . Processor  1402  may load a user interface program (e.g., a program stored in memory  1404  or another device or server) to determine how instructions or data received via an input component  1410  may manipulate the way in which information is provided to the user via an output component (e.g., display  1412 ). For example, processor  1402  may control the viewing angle of the visible information presented to the user by display  1412  or may otherwise instruct display  1412  to alter the viewing angle. 
     Electronic device  1400  may also be provided with a housing  1401  that may at least partially enclose one or more of the components of device  1400  for protecting them from debris and other degrading forces external to device  1400 . In some embodiments, one or more of the components may be provided within its own housing (e.g., input component  1410  may be an independent keyboard or mouse within its own housing that may wirelessly or through a wire communicate with processor  1402 , which may be provided within its own housing). All or a portion of housing  1401  can be finished, for example, to have an anodized electroplated aluminum finish according to embodiments of the invention. 
     The described embodiments of the invention are presented for the purpose of illustration and not of limitation.

Metadata:
Filing Date: 20120307
Publication Date: 20150915
Grant Date: 20150915
Priority Date: 20110307
Inventors: SILVERMAN KEN
MOLLER RONALD
RUSSELL-CLARKE PETER
PREST CHRISTOPHER D.
BHATIA RIMPLE
CHOINIERE PAUL
BROWNING LUCY ELIZABETH
TATEBE MASASHIGE
Assignee: APPLE INC
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