PATENT DOCUMENT

Publication Number: US-10532428-B2
Application Number: US-201715645780-A
Country: US
Kind Code: B2

Title: Interlocking flexible segments formed from a rigid material

Abstract:
A method for creating a flexible portion or bending portion within a rigid structure. The method can also be used for creating a flexible structure from a rigid material. The method includes providing a substantially rigid material, such as, but not limited to, metals, alloys, hard plastics, and the like, and selectively removing portions of the rigid material defining a geometric pattern in the rigid material. A bending radius of the flexible portion is defined by the geometric pattern. The rigid structure may be used to create an enclosure, a cover for an electronic device, one or more hinges, or the like.

Claims:
What is claimed is: 
     
       1. An electronic device comprising:
 an electronic component; and 
 an enclosure that protects the electronic component, the enclosure comprising:
 an enclosure top; 
 an enclosure bottom; and 
 an enclosure hinge that allows the enclosure top and the enclosure bottom to move relative to each other about a bend axis, wherein:
 the enclosure top comprises a first portion of a single piece of material; 
 the enclosure bottom comprises a second portion of the single piece of material; 
 the enclosure hinge comprises a third portion of the single piece of material that extends between the first portion of the single piece of material and the second portion of the single piece of material; 
 the third portion of the single piece of material comprises a plurality of apertures extending from a first surface of the third portion to a second surface of the third portion; 
 an aperture of the plurality of apertures varies in dimension as the enclosure top and the enclosure bottom move relative to each other about the bend axis; 
 a sidewall defines at least a portion of the aperture of the plurality of apertures and extends from a first end of the aperture at the first surface to a second end of the aperture at the second surface; and 
 the sidewall forms a non-perpendicular angle with the first surface of the third portion of the single piece of material. 
 
 
 
     
     
       2. The electronic device of  claim 1 , wherein:
 the plurality of apertures comprises:
 a first row of apertures arranged in a first direction aligned with the bend axis; 
 a second row of apertures arranged in the first direction; and 
 
 a third row of apertures arranged in the first direction; 
 the apertures of the third row of apertures are aligned with the apertures of the first row of apertures; 
 the apertures of the second row of apertures are misaligned with the apertures of the first row of apertures; and 
 the second row of apertures is positioned between the first row of apertures and the third row of apertures. 
 
     
     
       3. The electronic device of  claim 2 , wherein the apertures of the second row of apertures are also misaligned with the apertures of the third row of apertures. 
     
     
       4. The electronic device of  claim 2 , wherein each aperture of each one of the first, second, and third rows of apertures is diamond-shaped. 
     
     
       5. The electronic device of  claim 2 , wherein each aperture of each one of the first, second, and third rows of apertures varies in dimension as the enclosure top and the enclosure bottom move relative to each other about the bend axis. 
     
     
       6. The electronic device of  claim 1 , wherein the aperture of the plurality of apertures is diamond-shaped. 
     
     
       7. The electronic device of  claim 6 , wherein:
 the aperture of the plurality of apertures comprises two opposing and aligned apexes; and 
 a distance between the apexes varies as the enclosure top and the enclosure bottom move relative to each other about the bend axis. 
 
     
     
       8. The electronic device of  claim 7 , wherein the distance between the apexes is substantially perpendicular to the bend axis. 
     
     
       9. The electronic device of  claim 7 , wherein:
 the aperture of the plurality of apertures further comprises two opposing and aligned ends; 
 a distance between the ends varies as the enclosure top and the enclosure bottom move relative to each other about the bend axis; and 
 the distance between the ends is substantially parallel to the bend axis. 
 
     
     
       10. The electronic device of  claim 1 , wherein the sidewall forms a non-perpendicular angle with the second surface of the third portion of the single piece of material. 
     
     
       11. The electronic device of  claim 1 , wherein the sidewall is configured to limit an amount of movement of the enclosure top and the enclosure bottom relative to each other about the bend axis. 
     
     
       12. The electronic device of  claim 1 , wherein:
 the opening in the first surface has a first shape; 
 the opening in the second surface has a second shape; and 
 the first shape is different than the second shape. 
 
     
     
       13. The electronic device of  claim 1 , wherein:
 the enclosure at least partially surrounds the electronic component; and 
 the electronic component is one of:
 a keyboard; 
 a track pad; or 
 a display. 
 
 
     
     
       14. The electronic device of  claim 1 , wherein:
 the enclosure houses the electronic component; and 
 the electronic component is one of:
 a processor; or 
 a storage medium. 
 
 
     
     
       15. The electronic device of  claim 1 , wherein the enclosure is a laptop computer clamshell. 
     
     
       16. The electronic device of  claim 1 , wherein at least a portion of the first portion of the single piece of material defines at least a portion of a first wall of a space that holds at least a portion of the electronic component. 
     
     
       17. The electronic device of  claim 1 , wherein the single piece of material is a rigid material. 
     
     
       18. An enclosure housing an electronic component of an electronic device comprising:
 a first plurality of flex apertures defined within a rigid material along a first row; and 
 a second plurality of flex apertures defined within the rigid material along a second row, wherein:
 the second row is positioned below the first row; 
 the first plurality of flex apertures are misaligned with the second plurality of flex apertures such that a first end of each flex aperture of the first plurality of flex apertures is in a different vertical plane from a first end of each flex aperture of the second plurality of flex apertures; 
 when a bending force is applied to one of the first row and the second row, two opposing and aligned apexes of each aperture of each of the first plurality of flex apertures and the second plurality of flex apertures expand away from one another in a direction perpendicular to a bend axis, allowing the rigid material to bend about the bend axis; 
 the enclosure at least partially surrounds the electronic component of the electronic device when the enclosure is bent about the bend axis; 
 at least one flex aperture of at least one of the first plurality of flex apertures or the second plurality of flex apertures extends between an opening in a first surface of the rigid material and an opening in a second surface of the rigid material; 
 the opening in the first surface has a first shape; 
 the opening in the second surface has a second shape; and 
 the first shape is different than the second shape. 
 
 
     
     
       19. An electronic device comprising:
 an electronic component; and 
 an enclosure that protects the electronic component, the enclosure comprising:
 a first enclosure portion; 
 a second enclosure portion; and 
 a third enclosure portion that allows the first enclosure portion and the second enclosure portion to move relative to each other, wherein:
 the first enclosure portion comprises a first portion of a single piece of material; 
 the second enclosure portion comprises a second portion of the single piece of material; 
 the third enclosure portion comprises a third portion of the single piece of material that extends between the first portion of the single piece of material and the second portion of the single piece of material; 
 the third portion of the single piece of material comprises an aperture that varies in dimension when the first enclosure portion and the second enclosure portion move relative to each other; 
 the aperture extends between an opening in a first surface of the third portion of the single piece of material and an opening in a second surface of the third portion of the single piece of material; 
 the opening in the first surface has a first shape; 
 the opening in the second surface has a second shape; and 
 the first shape is different than the second shape.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 13/768,943, filed Feb. 15, 2013, which claims priority to U.S. provisional application No. 61/599,766, filed Feb. 16, 2012. The disclosure of each earlier application is hereby incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to creating flexible portions within a rigid material and more specifically, to creating flexible segments for components of electronic devices. 
     BACKGROUND 
     Many electronic devices, peripheral components or devices (such as speakers, headphones, keyboards, etc.) may include housings or enclosures made of a relatively rigid material, such as plastic or metal. These types of enclosures are typically at least somewhat rigid in order to provide protection for internal components housed within the enclosures. However, due to the rigidity of the material, in order for these type of enclosures or housings to bend or flex, a separate element, such as a hinge, may need to be connected to the rigid material. For example, laptop enclosures may include two separate rigid components interconnected together by one or more hinges that allow the two components to move relative to each other. These additional components, such as hinges, may increase the size of the enclosures and thus the size of the electronic devices or peripheral devices, as well as increase manufacturing costs as additional components may need to be assembled together. 
     SUMMARY 
     Examples of embodiments described herein may take the form of a method for creating an enclosure for an electronic device. The method includes providing a rigid material and removing sections of the rigid material to create a geometric pattern of interlocking features. The geometric pattern may define the flex of the rigid material. 
     Other embodiments may take the form of an enclosure formed of a substantially rigid material. The enclosure may include a first plurality of flex apertures defined within the rigid material along a first row and a second plurality of flex apertures defined within the rigid material along a second row. The second row is positioned below the first row and the first plurality of flex apertures are misaligned with the second plurality of flex apertures such that a first end of each of the first plurality of flex apertures is in a different vertical plane from a first end of each of the second plurality of flex apertures. When a bending force is applied to one of the first row or the second row, the first plurality of flex apertures and the second plurality of flex apertures vary in shape or dimension, allowing the rigid material to bend. 
     Yet other embodiments of the disclosure may take the form of a housing formed of a substantially rigid material. The housing may include a first plurality of interlocking features defined within the rigid material, a second plurality of interlocking features defined within the rigid material, and a plurality of flex apertures defined between the first plurality of interlocking features and the second plurality of interlocking features to separate the first plurality of interlocking features from the second plurality of interlocking features. The first plurality of interlocking features is movable relative to the second plurality of interlocking features. 
     Other embodiments of the disclosure may take the form of a method of manufacturing a flexible component. The method includes providing a substantially rigid material and removing portions of the rigid material to create a plurality of flex apertures. The flex apertures are defined by interlocking features of the rigid material, the interlocking features are adjacent to each other and spaced apart from one another by the flex apertures. Each one of the interlocking features has at least one sidewall and an angle of the sidewall determines a radial bend the rigid material. The rigid material formed using the disclosed method may be non-cylindrical, e.g., planar or a three-dimensional object that includes curves but is not substantially cylindrical. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a flow chart illustrating a method for creating a flexible portion within a rigid material. 
         FIG. 2A  is a front perspective view of an electronic device including an enclosure formed of a rigid material including a flexible portion. 
         FIG. 2B  is a side elevation view of the electronic device including a first embodiment of the enclosure. 
         FIG. 2C  is a side elevation view of the electronic device including a second embodiment of the enclosure. 
         FIG. 3A  is a top perspective view of the rigid material forming the enclosure prior to being formed with the flexible portion. 
         FIG. 3B  is a top plan view of the rigid material including a first embodiment of a geometric portion forming the flexible portion. 
         FIG. 4A  is an enlarged view of the geometric pattern of  FIG. 3B  during bending. 
         FIG. 4B  is a further enlarged view of the geometric pattern of  FIG. 3B  during bending. 
         FIG. 4C  is a simplified side perspective view of the enclosure of  FIG. 2A  including the geometric pattern of  FIG. 3B  with a top portion partially angled with respect to a bottom portion. 
         FIG. 4D  is a simplified side perspective view of the enclosure of  FIG. 2A  including the geometric pattern of  FIG. 3B  with the top portion positioned substantially parallel to the bottom portion. 
         FIG. 4E  is an enlarged side perspective view of the enclosure of  FIG. 4D . 
         FIG. 5A  is a top plan view of the rigid material including a second embodiment of a geometric pattern forming the flexible portion. 
         FIG. 5B  is a simplified side perspective view of the enclosure of  FIG. 2A  including the geometric pattern of  FIG. 5A  with the top portion positioned substantially parallel to the bottom portion. 
         FIG. 5C  is an enlarged top plan view of the geometric pattern of  FIG. 5A . 
         FIG. 5D  is an enlarged side elevation view of the geometric pattern of  FIG. 5A  with the enclosure in the position illustrated in  FIG. 5B . 
         FIG. 5E  is an enlarged top perspective view of the geometric pattern of  FIG. 5A . 
         FIG. 5F  is a top perspective view of a row of the geometric pattern of  FIG. 5A . 
         FIG. 6A  is a top perspective view of a row of a third embodiment of the geometric pattern forming the flexible portion. 
         FIG. 6B  is a top perspective view of two rows of the geometric pattern of  FIG. 6A . 
         FIG. 6C  is a side perspective view of a portion of the geometric pattern of  FIG. 6A . 
         FIG. 7A  is a top plan view of a fourth embodiment of the geometric pattern forming the flexible portion. 
         FIG. 7B  is a top perspective view of the geometric pattern of  FIG. 7A . 
         FIG. 7C  is a top plan view of an interlocking feature removed from the geometric pattern of  FIG. 7A . 
         FIG. 8A  is a perspective view of a pair of headphones including an enclosure with the geometric pattern of  FIG. 6A  defining the flexible portion. 
         FIG. 8B  is a side perspective view of one of the headphones bending by flexing along the flexible portion of the enclosure. 
         FIG. 9A  is a top plan view of a cover for an electronic device including a geometric pattern defined therein. 
         FIG. 9B  is a side elevation view of the cover and the electronic device of  FIG. 9A  with the cover partially retracted. 
         FIG. 9C  is a top perspective view of the cover and the electronic device of  FIG. 9A  with the cover fully retracted and acting as a support or stand for the electronic device. 
     
    
    
     DETAILED DESCRIPTION 
     Some embodiments described herein may take the form of a method for creating a flexible portion or element within a rigid or substantially rigid material. It should be noted that the term rigid material as used herein is meant to encompass rigid materials, semi-rigid (partially flexible materials), and substantially any materials where an increased flexibility may be desired. For example, the rigid material may be metal, carbon fiber, composites, ceramics, glass, sapphire, plastic, or the like. The flexible portion or portions defined in the rigid material may function as a living hinge or mechanical hinge and allow the rigid material to bend to a predetermined angle in a predetermined direction. In some embodiments, the flexible portion may be positioned at substantially any location of the rigid material and may span across one or more dimensions of the rigid material (e.g., across a width, length, or height of the rigid material). In some instances, the rigid material may be substantially flat or planar, may represent a three-dimensional object (e.g., a molded or machined component), or the like. 
     The flexible portion may be defined by a geometric pattern that may be recessed and/or cut into the rigid material. In some embodiments, the geometric pattern may define one more movable elements that are interlocked together. The movable elements or interlocking features may move relative to adjacent elements, but may be prevented from disconnecting from those adjacent elements. The flexible portion may include a plurality of movable interlocked elements, each of which may move a predetermined amount, so that the combination of the plurality of movable elements creates a bend point or area for the rigid material or device or enclosure made from the material. The amount of bending, that is, the maximum angle through which the rigid material can deform if all movable interlocked elements translate to their maximums, may be varied by changing either the degree of movement between individual interlocked movable elements or the shape of one or more elements. Similarly, the bend angle, direction, pitch, and bend or flexing axis may vary with the geometric pattern of the cuts. For example, a first geometric pattern may allow the rigid material to only bend along a single axis where as a second geometric pattern may allow the rigid material to bend along multiple axes. As another example, by varying the angulation of the shape of the elements, the flexing radius may be modified. 
     The rigid material may include one or more different patterns, angles, or the like. In other words, the rigid material may have some sections that are more flexible than others, which may be done by modifying the geometric pattern, the angulation of the pattern, or the like. 
     In some embodiments, the method for creating the flexible portion may be used to create enclosures for electronic devices, including portable and/or peripheral devices. For example, an enclosure for a laptop may be created from a rigid material having a flexible portion defined around approximately a midpoint of the material. The flexible portion may allow the rigid material to be folded in half and thus acts as a laptop clamshell. A top portion may support a display screen and a bottom portion may support a keyboard, track pad, and the like, while an interior defined by sidewalls of the rigid material may house a variety of electronic components in accordance with conventional laptop computing devices. In this manner, the enclosure (or a portion thereof) may be created from a single rigid material, while still providing flexibility and bending for the enclosure. As another example, the method may be used to create a flexible cover for an electronic device, such as a cover for a tablet computer or smart phone. 
     As another example, the method may be used to create a housing or a portion of a housing for headphones. In this example, the flexible segments may cooperate to form an enclosure encompassing, and protecting, a wire where it enters the enclosure of the headphone. The enclosure at the connection location to the wire or cable may flex around one or more axes to provide bending in multiple directions. This flexibility may substantially prevent the enclosure from cracking as the wire moves relative to the earpieces because the connection portion of the earpiece may move, at least in part, with the movement of the communication wire. Additionally, the flexibility may also help to prevent internal wires of the cable from breaking as the flexibility of the housing may increase the radius that the cable or wire may bend, thus providing strain relief to the internal wires as it is bent. 
     Yet other examples include using the method to create bands, straps, or cables having flexible sections or that may be substantially flexible. As a specific example, the method may be used to create a band that may support an electronic device, such as an arm band for holding a portable electronic device on a user&#39;s bicep. As another specific example, the method may also be used to create strain relief sections for cables, straps, or the like. The method may further be used to create handles, cases, bags, purses, or the like. 
     Turning now to the figures, a method for creating a flexible portion in a rigid material will be discussed in more detail.  FIG. 1  is a flow chart for a method  100  for creating a flexible portion within a rigid material. The method  100  may begin with operation  102  and the rigid material may be formed or otherwise provided. In some embodiments, the rigid material may be metal injection molded into a desired shape, the shape of the rigid material may be milled or otherwise cut from a block or sheet of material, or other manufacturing techniques may be used. The rigid material may be substantially any material where an increased flexibility is desired. For example the material may include metals, metal alloys, plastics, composite materials (e.g., carbon fiber reinforced plastic, magnetic or conductive materials, glass fiber reinforced materials, or the like), ceramics, sapphire, glasses, printed circuit boards, and the like. Additionally, the rigid material may include a combination of two or more materials connected together (e.g., through adhesive, welding, or the like). As one example, in instances where a first material may be brittle (e.g., glass), the material may be laminated or otherwise connected to another less brittle material and then the combined material may be modified using the method  100 . 
     The formation process used in operation  102  to create the rigid material may be varied depending on the type of material used and/or the size/dimensions of the desired shape. For example, in instances where the material is a hard plastic, injection molding may be used to create the material. However, injection molding may not be desired for other types of materials. Additionally, operation  102  may be optional. For example, in some instances, the rigid material may be provided from another source (e.g., manufacturer) and then may be manipulated, as discussed in more detail below, to provide the flexible portion. Accordingly, in some instances, the rigid material may be in the form of a three-dimensional shape, such as the formed shape of a molded or milled component. Also, it should be noted that the thickness of the rigid material may vary as desired based on the use of the material or shape of the component. 
     The shape of the rigid material after operation  102  may not be the final shape of the component as some features such as a small or complex apertures, or finishes such as rounded edges, coatings, painting, and the like may be completed after the method  100  has completed. In other embodiments, such as those where the rigid material may be injection molded, the shape of the rigid material after operation  102  may be substantially the same as the final shape of the rigid material (excluding the changes in shape due to operation  108  discussed in more detail below).  FIG. 3A  illustrates a top plan view of the rigid material after operation  102 , and is discussed in more detail below. Alternatively or additionally, the rigid material may include one or finishes, coatings, decorations, or the like, prior to being manipulated during the method  100 . For example, the rigid material may be painted, anodized, layered with one or more coatings, films, or the like, may be applied to the material prior to operations  104  and  106  (discussed below). 
     After operation  102  and the shape of the rigid material is created, the method  100  may proceed to operation  104  and a geometric pattern may be determined. In operation  104 , the desired bending direction or axis, bending angle or degree, size of apertures within the material, and/or spring rate for the flexible portion may be analyzed to determine the desired geometric pattern. The geometric pattern may be created by a processor executing one more algorithms or may be determined by a user. The pattern may take into account a number of desired characteristics for the flexibility of the rigid material. For example, increasing the angle of the cuts in the geometric pattern may increase the bending radius of the material. As another example, decreasing the width of the cuts or the removed material may reduce the bending radius. In addition to the bending characteristics listed above, there may be additional characteristics of the geometric pattern, such as an aesthetic appearance of the pattern, type of material to be used, and so on that may also be taken into account. Different examples of geometric patterns having one or more of the above listed characteristics are discussed in more detail below with respect to  FIGS. 4A, 5A, 6A, and 7A . 
     The geometric pattern chosen may include one or more patterns. For example, a first section of the material may be selected to have a first geometric pattern with a first bend radius whereas a second section of the material may be selected to have a second geometric pattern with a second bend radius. In this manner, the two sections of the material (when finished) may have different bend flexibilities. As another example, a first side of the material may include a first geometric pattern and a second side of the material may include a second geometric pattern. In other words, the front side pattern may not match the backside pattern. In this manner, the material may have a first bend radius when bent in a first direction (e.g., the front rolled upon itself) and a second bend radius when bent in a second direction (e.g., the back side rolled upon itself). 
     Once the geometric pattern has been determined, the method  100  may proceed to operation  106  and the pattern may be provided to a cutting mechanism or device. In some embodiments, the geometric pattern may include sharp corners and/or small apertures. In these embodiments, the cutting device may be a laser cutting machine, which may use a laser to cut or engrave the geometric pattern into the rigid material. In other embodiments, the cutting device may be an electrical discharge machine, which may use a wire or probe to remove material in the shape of the geometric pattern. In either of these embodiments, the geometric pattern may be provided to the cutting device in the form of data. For example, the geometric pattern may be provided to the cutting device by communicating data, such as in the form engineering drawings, computer aided design (CAD) files, computer aided manufacturing (CAM) files, or computer numerical control (CNC) files, to a processor or other component within the cutting device. 
     After operation  106 , the method  100  may proceed to operation  108  and the geometric pattern may be incorporated into the rigid material. In some embodiments, the cutting device may remove sections or portions of the rigid material to form the geometric pattern. For example, in instances where the cutting device is a laser, a laser beam may cut apertures into the rigid material or remove one or more layers of the rigid material to create a recess within the rigid material. The laser beam may melt, cut, burn, and/or vaporize the material to create the apertures and/or recesses (engraved portions) within the rigid material. In embodiments utilizing a laser as the cutting mechanism, the laser may include a multi-axis head that can shift as appropriate to create the angulation and other requirements of the geometric pattern or patterns. For example, the position of the head of the laser may be modified based on the shape of the cuts, while maintaining a single cut through a portion of the material. 
     In other embodiments, for example, where the cutting device is a water jet or other pressurized cutter, the material may be removed by a pressurized stream water which may optionally include one or more abrasive materials to assist in removing the rigid material. Other cutting devices are also envisioned, but may depend on the complexity of the geometric pattern and/or the type of material for the rigid material. For example, electrical discharge machining (EDM) may be used and a wire or probe may be used to remove material in the shape of the geometric pattern. 
     It should be noted that certain portions of the geometric pattern may have apertures defined through the rigid material, whereas other portions of the geometric pattern may include recesses defined only through one or two layers of the rigid material (that is, they do not pierce through the rigid material). 
     After operation  108  in which the geometric pattern has been engraved and/or cut into the rigid material, the method  100  may proceed to operation  110 . In operation  110 , a computer and/or a user may determine whether another component should be manufactured. If another component is to be manufactured, the method  100  may return to operation  102 . However, if another component is not going to be manufactured, the method  100  may terminate at an end state. 
     Alternatively, in instances where the material and/or the component may not be finalized or otherwise requires additional processing, the method may include an additional operation of finalizing or finishing the material. For example, one or more coatings, paints, decorations, or finishes may be applied to the material after it has been cut. In instances where finishes may be applied after the material has been cut with the geometric pattern, the coatings may be applied to extend around the sidewalls of the material formed by the cuts. However, as discussed above, in some embodiments, the material or component may be substantially finalized or otherwise may include the desired finishes prior to being cut. In these instances, the material may not need to be further processed. Moreover, it should be noted that the flexible sections may be created in a rigid material that is mounted within another component or fixture. 
     The method  100  may also be used to create components having one or more flexible portions or components that are entirely flexible. In some embodiments, sheets or large portions of a rigid material may be cut using the method  100 , and once cut with a geometric pattern, one or more shapes or smaller components may be cut therefrom. For example, a large sheet of a rigid material may be cut with a geometric pattern along its entire length and then a plurality of smaller pieces of the material may be cut or stamped from the large sheet. In this example, the smaller pieces may be entirely flexible along their entire length, width, or other dimension. As another example, the rigid material that is cut using the method  100  may include one or more extrusions, apertures, or the like. As a specific example, a hole or aperture may be cut into a center of the rigid material (before or after the rigid material is processed using the method  100 ) and the geometric pattern may extend around the aperture. In this example, the edges of the aperture may flex due to the geometric pattern, allowing the material surrounding the aperture to remain flexible. 
     The method  100  and the geometric patterns discussed in more detail below may be used to create interlocking segments for a material, where the material shape may not be cylindrical. The geometric patterns, such as those patterns utilizing angled sidewalls or angulation, may allow sheets and other non cylindrical items to be cut and remained remain connected together. In other words, rather than relying solely on the shape of the object itself to maintain the connection of the components of the geometric pattern, the geometric pattern, rather than the shape of the object, may be used to allow the object to remain interconnected, despite the apertures defined through the object. Thus, the method  100  may be used to create components and materials for a number of different apparatuses and items. 
     Illustrative enclosures formed using the method  100  of  FIG. 1  will now be discussed.  FIG. 2A  is a perspective view of an electronic device  200  including an enclosure  202  formed of a substantially rigid material  230  including a strain relief or flexible portion  204 . The enclosure  202  may at least partially surround one or more components of the electronic device  200 , such as a keyboard  206 , track pad  208 , and/or a display  210 . Further, although not shown, the enclosure  202  may house one or more internal components (also not shown) of the electronic device  200 , such as a processor, storage medium, and so on. It should be noted that, although the electronic device  200  in  FIG. 2A  is illustrated as a computer, other electronic devices are envisioned. For example, the enclosure  202  may be used for smart phones, digital music players, display screens or televisions, video game consoles, set top boxes, telephones, and so on. The method  100  may also be used to create enclosures (or portions thereof) for one more peripheral devices such as keyboards, mice, connection cables or cords, earphones, and so on. Further, the method  100  may be used to create bands (such as an arm band to support an electronic device), garage doors, straps, handles, cases, bags, covers for electronic devices such as tablet computers or electronic reading devices, shades or blinds, and substantially any other components which may require flexibility. 
     The enclosure  202  may also include one or more connection apertures  212  defined therein. The connection apertures  212  may be defined during the method  100 , or in another manner (e.g., while the rigid material is being formed). The connection apertures  212  may receive one or more cables, such as communication, data, and/or power cables, to provide a connection port for the those cables to the electronic device  200 . For example, the connection apertures  212  may define an input/output port for universal serial bus (USB) cable, a power cable, or a tip ring sleeve connector. The position, size, number, and/or shape of the connection apertures may be varied depending on the desired connectivity for the electronic device  200 . 
     The flexible portion  204  of the enclosure  202  may allow the enclosure  202  (specifically, the rigid material  230 ) to bend in at least one direction.  FIG. 2B  is a side elevation view of the electronic device  200  in a closed position, with the enclosure  202  folded at the flexible portion  204 . The enclosure  202  may bend so that a top  224  of the enclosure  202  may be folded onto or positioned adjacent to a bottom  226  of the enclosure  202 . In other words, the top  224  may be rotated from a perpendicular, obtuse, or other angular orientation with respect to the bottom  226  (see  FIG. 2A ) to a substantially parallel orientation with the respect to the bottom  226 . For example, in instances where the electronic device  200  is a laptop computer, the display  210  may be operably connected to the top  224  and may be rotated downwards towards the bottom  226 , closing the electronic device  200 . In this manner, the enclosure  202  may function as a clamshell in that it may selectively rotate around an axis to position the top  224  relative to the bottom  226 . It should be noted that in other embodiments, both the top and bottom  224 ,  226  may rotate relative to each other or only one of the top or bottom  224 ,  226  may rotate. The flexible portion  204  and the rotation of the top  224  and bottom  226  will be discussed in more detail below. 
     With reference to  FIGS. 2A and 2B , the top  224  and bottom  226  may include one more portions operably connected together. The top  224  may include a first or outer portion  214  and a second or inner portion  216  operably connected to define a cavity within the top  224 . Similarly, the bottom  226  may include a first or outer portion  218  and a second or inner portion  220  that may be operably connected together to define a cavity within the bottom  226 . The cavities (not shown) may receive the one or more internal components of the electronic device  200 , as well as may at least partially receive the display  210 , the keyboard  206 , and/or the track pad  208 . 
     In some embodiments, the outer portion  214 ,  218  may have substantially the same depth as the respective inner portion  216 ,  220 . In other words, the outer portion  214  may have a depth that may be approximately half the depth of the cavity and the second portion  216  may have a depth that may have approximately half of the depth of the cavity. In these embodiments, the outer portions  214 ,  218  may be formed of a single rigid material  230  and the inner portions  216 ,  220  may be formed of a separate rigid material that may be operably connected to the outer portions  214 ,  218 . 
     With reference to  FIG. 2B , in embodiments where the top  224  and bottom  226  include two or more portions  214 ,  216 ,  218 ,  220 , the outer portions  214 ,  218  may include the flexible portion  204  and the inner portions  216 ,  220  may include an inner or second flexible portion  228 . The inner flexible portion  228  may be substantially the same as the outer flexible portion  204 , so that the inner portions  216 ,  220  may have approximately the same bend angle and movement range as the outer portions  214 ,  218 . The second inner flexible portion  228  defined on the inner portions  216 ,  220  may be substantially similar to the flexible portion  204 . 
     In other embodiments, the inner portions  216 ,  220  may be panels or plates, or may have otherwise have a reduced depth compared to the depth of the outer portions  214 ,  218 . In yet other embodiments, the top  224  and bottom  226  may include a single portion, and the cavity may be created by removing material through one or more apertures within the top  224  and/or bottom  226 .  FIG. 2C  is a side elevation view of the top  224  and bottom  226  formed of a single rigid material  230 . For example, the top  224  may be at least partially hollowed out to define a surface and four sidewalls extending therefrom, and the display  210  may be operably connected to the surface and sidewalls to enclose the surface. Similarly, the bottom  226  may be formed to receive the keyboard  206 , which may form the cover portion for the bottom  226  cavity to cover the internal components. The construction of the enclosure  202  may be varied depending on the desired size, dimensions, and/or electronic device  200  be housed by the enclosure  202 . 
     In embodiments where either the outer portions  214 ,  218  and/or the inner portions  216 ,  220  may from a panel or cover, the respective portions may terminate prior to the flexible portion  204  and thus the flexible portion  204  may form the entire hinge for the top  224  and bottom  226 . Similarly, in embodiments where the top  224  and bottom  226  are formed of a single portion as shown in  FIG. 2C , the flexible portion  204  may form the only hinge for the enclosure  202 . In these embodiments, a single material portion may form the entire enclosure  202 . That is, the enclosure  202  may be substantially unibody in that it may be formed form a single piece of material. However, due to the flexible portion  204 , discussed in more detail below, the enclosure  202  may bend in order to fold the top  224  towards the bottom  226  or vice versa. Briefly, the flexible portion  204  includes a geometric pattern including interconnected elements that may move or change shape relative to each other in order to provide a flexibility to the rigid material  230  forming the enclosure  202 . 
       FIG. 3A  is a top perspective view of an at least partially rigid material  230  prior to being formed with the flexible portion  204 . The rigid material  230  may form one of the outer portions  214 ,  218  and/or one of the inner portions  216 ,  220  (see  FIG. 2B ). In other embodiments, the rigid material  230  may form both the top  224  and bottom  226  when formed of a single portion (see  FIG. 2C ). 
     As described above, with respect to  FIG. 1 , the method  100  may be used to create the flexible portion  204  within the rigid material  230  by defining a geometric pattern into the rigid material  230 .  FIG. 3B  is a top plan view of the rigid material  230  including a geometric pattern  232 .  FIG. 4A  is an enlarged top plan view of the rigid material  230  with a geometric pattern  232  formed therein to define the flexible portion  204 . The geometric pattern  232  may be varied depending on the desired bend angle, position, spring rate, and the like. In one embodiment, as shown in  FIG. 4A , the geometric pattern  232  may be a series of interconnected flex apertures  234  positioned apart from one another to define spacing sections or interlocking features  236 . There may be one or more rows  238 ,  240  of flex apertures  234  that may be misaligned from one another. For example, a first row  238  may include flex apertures  234  offset from flex apertures  234  within a second row  240  positioned directly below the first row  238 . In this manner, the flex apertures  234  of adjacent rows  238 ,  240  may begin and terminate at varying locations from one another. 
     The flex apertures  234 , as discussed in more detail below, may be generally linearly shaped apertures formed within the rigid material  230 . In some instances, the flex apertures  234  may have a diameter or width that may be selected so that before the rigid material  230  is flexed or bent, the flex apertures  234  may not be substantially visible, improving the aesthetic appearance of the rigid material  230 . In other words, prior to bending, the flexible portion  204  may not substantially stand out in appearance from the other surfaces of the rigid material  230 . 
     During the method  100 , the flex apertures  234  may be formed so that the sidewalls surrounding each aperture  234  may have different angular orientations throughout the thickness of the material  230 . That is, the flex apertures  234  may have different dimensions through the thickness of the material  230 , as the sidewalls  254  may vary in angular orientation (width). The varying dimensions of the flex apertures  234  may allow the rigid material  230  forming the sidewalls  254  to be able to bend or fold, while still maintaining structural strength. 
     With reference to  FIG. 4A , the combination of the first row  238  and the second row  240  may be repeated throughout a length of the flexible section  204 . For example, a third row  242  may include flex apertures  234  that may be substantially aligned with the flex apertures  234  of the first row  238 . Similarly, a fourth row  244  may include flex apertures  234  that may be substantially aligned with the flex apertures  234  of the second row  240 . In these embodiments, the flex apertures  234  may be considered to be aligned if a first end  246  of the flex aperture  234  is positioned in a same vertical plane as the first end  246  of another flex aperture  234  and a second end  248  may be positioned in a same vertical plane as the second end  248  of another flex aperture  234  in another row. 
     The shape and/or dimensions of the flex apertures  234  may be varied depending on the desired flexibility of the rigid material  230 . For example, the larger the flex apertures  234 , the larger the flexibility of the rigid material  230 ; however, the increase in size of the flex apertures  234  may lead to a corresponding reduction in rigidity and/or strength for the rigid material. Accordingly, the size of the flex apertures  234  may be balanced against a desired level of rigidity required to best protect the internal components of the electronic device  202   200  from damage. 
       FIG. 4B  is an enlarged view of a portion of the geometric pattern  232  during bending. With reference to  FIGS. 4A and 4B , in some embodiments, as the rigid material  230  bends along the flexible portion  204  the flex apertures  234  may deform or stretch to be generally diamond shaped as rigid material  230  is stretched. Specifically, in some embodiments, the flex apertures  234  may be generally linearly shaped when formed and during bending may stretch for form a diamond shape in order to accommodate the bending force without breaking the material  230 . For example, from the first end  246 , the aperture may expand in a triangularly shaped manner, to form two apexes  250 ,  252 , a top apex  250  and a bottom apex  250 ,  252 . The two apexes  250 ,  252  may be aligned with one another, such that the top apex  250  may be positioned over the bottom apex  252 . From the two apexes  250 ,  252  the aperture  234  may descend downwards towards the second end  248 . The second end  248  may be substantially laterally aligned with the first end  246 . As the bending force is applied to the rigid material  230 , the top surface of the flex aperture  234  and the bottom surface may expand away from each other to define the apexes  250 ,  252 . As the bending force increases, the apexes  250 ,  252  may expand farther away from one another. 
     In other embodiments, the flex apertures  234  may be diamond shaped when formed, and thus the diamond may be expanded rather than the portions of a linear line expanding into a diamond shape due to the bending force. 
     It should be noted that in some embodiments after bending, the rigid material  230  may experience some plastic deformation in that the shape of the flex apertures  234  may be somewhat deformed and remain in the diamond shape, rather than the linear shape as originally formed. However, in other embodiments, due to the reduced thickness of the sidewalls  254 , the sidewalls  254  may resiliently return to their original shape, so that after the bending force is removed the shape of the flex apertures  234  when the bending ends, may return to the original linear shape. 
     The flex apertures  234  may be defined by sidewalls  254  within the rigid material  230 . That is, the flex apertures  234  may be defined by the material surrounding the portions of material removed by the cutting machine during operation  108  of the method  100  in  FIG. 1 . The sidewalls  254  may allow the size of the flex aperture  234  to vary in dimension as the flexible portion  204  bends. For example, the two apexes  250 ,  252  may extend away from each other to increase the size of the flex aperture  234  or may extend towards each other to decrease the size of the flex aperture  234 . Similarly, the two ends  246 ,  248  may be compressed towards each other or extend away from each other to vary the size of the flex aperture  234 . 
     As briefly discussed above, in some embodiments, the shape of the flex apertures  234  may change along a depth or thickness of the rigid material  230 . For example, on a first side  260  of the material  230 , the flex apertures  234  may have a first size and/or shape and on a second side  262  of the material  230  the flex apertures  234  may have a second size and/or shape. This may be possible as the sidewalls  254  may vary in size along a thickness of the material.  FIG. 4C  is a side perspective view of the rigid material  230  being partially bent.  FIG. 4D  is a side perspective view of the rigid material  230  being more fully bent. As shown best in  FIG. 4E , a first side  260  of the flex aperture  234  may have a smaller diameter and a second side  262  of the flex aperture  234  may have a diameter that is larger than the diameter on the first side  260  of the material  230 . In this manner, the sidewalls  254  may form a triangular or frustum shape in profile. 
     This may also allow the geometric pattern to be varied between the first side of the material  260  and the second side  262  of the material. In other words, the first side  260  may include a first geometric pattern and the second side may include a second geometric pattern, one or both patterns may also be selected not only for angulation and bend radius, but also based on aesthetics. As one example, the first side geometric pattern may be selected based on its bending properties and the second side geometric pattern may be selected based on its aesthetic properties. However, in other embodiments, the geometric pattern on both sides of the material may be selected to be substantially identical. 
     The triangular shape of the sidewalls  254  (in profile) may help to prevent the sidewalls  254  of adjacent rows  238 ,  240  from encountering each other as the rigid material  230  is folded or otherwise bent. Further, the triangular shape of the sidewalls  254  may allow the flex apertures  234  to be more flexible on the inner surface  262  of the material  230  than on the outer surface  260  as the sidewalls  254  may be thicker in width towards the outer surface  260 . The angular orientation of the sidewalls  254  may also act as a “stop” to prevent, reduce, or resist bending in a particular direction. This may help to protect internal components of the electronic device  200  from damage. For example, as the rigid material  230  may be used to form the enclosure  202 , the angular orientation of the sidewalls  254  may prevent bending past a predetermined angle so that enclosure  202  does not “over bend” and potentially damage internal components from damage. Additionally, the angle of the sidewalls  254  may prevent or substantially resist bending in a particular direction. Further, by varying the thickness or size of the sidewalls  254 , the flexible portion may become more or less rigid. 
     The shape of the sidewalls  254  may allow the flex apertures  234  to have an increased expansion during bending in the middle of each aperture  234 , which may simultaneously minimize stresses on the sidewalls  254  surrounding the apertures  234 . This allows the flexible portion  204  to bend without breaking or cracking the rigid material  230 , including the sidewalls  254  surrounding each of the flex apertures  234 . 
     With reference to  FIGS. 4D and 4E , due to the geometric pattern  232 , the flexible portion  204  may bend along one or more axes, although the flexible portion  204  may be an integral portion of the rigid material  230 . In  FIGS. 4D and 4E , the top  224  is shown folded over the bottom  226 . To cause the top  224  to be forced towards the bottom  226 , a force may be applied to the top  224  compressing it towards the bottom  226  and the flex apertures  234  surrounding a rotation axis A may vary in size. Some of the flex apertures  234  may expand whereas others may decrease. Additionally, the sidewalls  254  surrounding the rotation axis A may be compressed towards one another. This is possible as a thickness of the sidewalls  254  may be decreased on the inner side  262  of the rigid material  230  (due to the shape of the flex apertures  234 ), which provides additional flexibility to the rigid material  230  and specifically the sidewall  254 . The rotation axis A may be varied depending on the position of the compression force acting on the top  224 . 
     As shown in  FIG. 4D , in a second position of the enclosure  202 , the top  224  may be positioned substantially parallel to the bottom  226 , and depending on the thickness of the top  224  and/or bottom  226 , the top  224  and bottom  226  may be positioned in contact with one another. In some embodiments, the flexible portion  204  may have a spring force, such that as the flex apertures  234  vary in shape to accommodate the bending forces of the top  224  and/or bottom  226 , a spring force may accumulate. In these embodiments, depending on the weight of the top  224  (and other components operably connected thereto), when the bending force is released, the flexible portion  204  may return to an open or first position. However, in other embodiments, the weight of the top  224 , the spring force of the flexible portion  204 , or the weight of any components operably connected to the top  224  may allow the top  224  to remain in position until adjusted by a user or the like. For instance, after the top  224  has been positioned in the closed position, it may remain substantially in position, at least partially parallel to the bottom  226 . In yet other embodiments, the geometric pattern  232  may be varied so that the flex apertures  234  may be configured to maintain the enclosure  202  in a predetermined position. For example, the geometric pattern  232  may be configured so that the sidewalls  254  may be substantially rigid or may deform slightly so that after the bending force is removed, the rigid material  230  may remain in the bent position. For example, certain portions of the geometric pattern  232  may have different shapes, sizes, or other characteristics in order to allow the enclosure  202  to remain in a partially bent or fully bent configuration when the bending force is removed. 
     The geometric pattern  232  may be varied to alter one or more characteristics, such as the maximum bend angle or direction, of the flexible portion  204 .  FIG. 5A  is a top plan view of the rigid material  230  including another embodiment of the geometric pattern  282 .  FIG. 5B  is a side elevation view of the rigid material  230  including the geometric pattern  282  in a bent position.  FIG. 5C  is an enlarged top elevation view of flexible portion  204  of  FIG. 5A .  FIG. 5D  is an enlarged view of a row of the geometric pattern removed from the rigid material  230 .  FIG. 5E  is an enlarged view of the geometric pattern  282  in  FIG. 5B . The geometric pattern  282  in this embodiment may include one or more interlocking features  286  separated from one another by flex apertures  284 . Each of the interlocking features  286  may move relative to adjacent interlocking features  286  due to the flex apertures  284 . Thus, in these embodiments, the flex apertures  284  may not stretch or expand due to the bending force as in the  FIG. 4A  embodiment, but rather may be increased or decreased due to the relative movement of the interlocking features  286  with respect to each other. 
     The interlocking features  286  may be shaped in a number of different manners, which may vary the bending available for the flexible portion  204 . With reference to  FIG. 5D , in some embodiments, the interlocking features  286  may include a narrow neck  302  extending from an edge of the rigid material  230  or for interlocking features  286  within an inner portion of the geometric pattern  282 , a strip  312  of material. The neck  302  may expand outwards forming a head  304 . The neck  302  and the head  304  may form an inverted frustum, with the head  304  extending away from the edge  306  of the rigid material  230  or an edge of the strip  312 . 
     Adjacent interlocking features  286  extending from the same edge  306  or strip  312  may be substantially similar. As the flex apertures  284  are defined by the sidewalls of the interlocking features  286 , the perimeter of the flex apertures  284  may generally trace the perimeter of the interlocking features  286 . As such, the flex apertures  284  may also be generally frustum shaped. However, the flex apertures  284  may be aligned oppositely to the interlocking features  286  (for a single row  298 ,  300 ) such that the head or wide portion  308  of the flex aperture  284  may extend into the strip  312  of material, whereas the head  304  of the interlocking features  286  may extend away from the strip  312 . Further, the flex apertures  284  may be cut between rows to define the interlocking features  286 , and as such, the interlocking features  286  of vertically adjacent rows may be received in the flex apertures  284  of the adjacent row and the flex apertures  284  may separate rows of interlocking features  286  from each other. The width of the flex apertures  284  may be selected based on a desired bend radius of the material. For example, the finer the width of the flex apertures  284 , the smaller the bend radius. 
     The flex apertures may be integrally formed apertures that extend along an entire dimension of the rigid material, e.g., along the entire length or width. The flex apertures may form curved or undulating lines that separate two portions of the material from each other by a spacing gap. Due to the curved nature of the flex apertures, the interlocking features may be locked together, although the material may be disconnected by the flex apertures. The spacing gap or the size of the flex apertures may be varied between a first side of the material and a second side of the material. 
     With continued reference to  FIGS. 5A and 5C , there may be one or more rows  298 ,  300  of interlocking features  286  defined within the rigid material  230 . The number of rows  298 ,  300  may depend on the desired amount of bending or flexibility for the rigid material  230 . The more rows  298 ,  300  within the geometric pattern  282 , the more portions of the rigid material  230  may be flexible. In some embodiments, the rows  298 ,  300  may define strips  312  or lengths of rigid material  230  having interlocking features  286  extending from either side. For example, a row  298 ,  300  may be positioned between two other rows, and thus may include interlocking features  286  extending from opposite sides thereof in order to interlock with the adjacent rows. As another example, the rigid material may have a plurality of rows that extend along its entire length or width, so that the material may be flexible along an entire dimension. 
     With reference to  FIG. 5E , the interlocking features  286  may include sidewalls  294  forming an outer perimeter of each respective interlocking feature  286 . The sidewalls  294  may extend between the inner surface  262  and the outer surface  260 . In some embodiments, the sidewalls  294  may vary in thickness between the inner surface  262  and the outer surface  260 . In these embodiments, the sidewalls  294  may angle upwards from one surface  260 ,  262  towards the other, such that the angle of the sidewalls  294  with respect to a plane of the outer surface  260  may vary along the depth or thickness of the sidewall  294 . Additionally, the sidewalls  294  may be varied in angular orientation from each other (with respect to the plane of the outer surface  260 ). For example, as shown in  FIG. 5F , the first sidewall  316  may extend into the flex aperture  284  and a second sidewall  314  may extend away from the flex aperture  284 . 
     With reference to  FIGS. 5F and 5E , in some instances, a first sidewall  316  may form a first side of the interlocking feature  286  and the second sidewall  314  may form a second side of the interlocking feature  286 . Accordingly, the first side of the interlocking feature  286  may be angled inwards from the outer surface  260  to the inner surface  262  and the second side of the interlocking feature  286  may be angled outwards from the outer surface  260  to the inner surface  262 . In some embodiments, laterally adjacent interlocking features  286  may have opposite sides that extend inwards or outwards. For example, a first interlocking feature  286  may have a right side extending inwards and a left side extending outwards and a second interlocking feature  286  adjacent to the first interlocking feature  286  may have a right side extending outwards and a left side extending inwards. 
     The angled sidewalls may allow the base or rigid material to be shaped in a number of different ways. For example, the angled walls may allow the rigid material to have a substantially planar shape and as the material bends (due to the flex apertures), the flex apertures may remain interconnected through the angled walls. Additionally, the pitch of the sidewalls may be varied to vary the bending radius, and the pitch may be variable in the material, such that certain portions of the material may have a first bending radius and other portions of the material may have a second bending radius. 
     With continued reference to  FIG. 5F , as viewed from the top plan view, along the outer surface  260  the interlocking features  286  may appear to be substantially the same dimensions. However, along the inner surface  262 , the interlocking features  286  may have varying sidewall  294  thicknesses. For example, a first flex aperture  290  may have a decreased diameter along the inner surface  262  as compared with a second laterally adjacent flex aperture  292 . The varying thicknesses, may allow laterally adjacent interlocking features  286  to have differing angles of movement. A first interlocking feature  286  received within the first flex aperture  290  may be able to extend downwards towards the inner surface  262 , whereas a second interlocking feature  286  received within the second flex aperture  292  may not be able to extend the same amount inwards towards the inner surface  262  due to the decreased size of the second flex aperture  292 . Conversely, the first interlocking feature received within the first flex aperture  290  may not be able to extend as far upwards towards the outer surface  260  as the second interlocking feature received within the second flex aperture  292 . 
     In embodiments where the interlocking features  286  have varying angled sidewalls  294 , the dimensions of the flex apertures  284  defined by laterally adjacent interlocking features  286  may be different from each other. That is, a first flex aperture  290  may be larger (when viewed from the inner surface  262 ) than a second flex aperture  292  defined along the same row  298  and laterally adjacent to the first flex aperture  290 . The varying dimensions of the flex apertures  284  due the varying angular changes of the sidewalls  294 , may function to interlock the interlocking features  286  from adjacent rows together, while still allowing the interlocking features  286  to move relative to each other. 
     With reference to  FIGS. 5B and 5E , bending the rigid material  230  will now be discussed in more detail. As a force is applied to one or both of the top  224  and bottom  226 , the rigid material  230  may bend along an axis A positioned within the flexible portion  204 . The force may cause one or more rows  298 ,  300  of the interlocking features  286  to move relative to each other. For example, as shown in  FIG. 5E , select interlocking features  286  may extend slightly outwards away from a plane of the material  230 . However, due to the alternating sidewall  314 ,  316  thicknesses and the flex apertures  284  dimensions, the interlocking features  286  may remain substantially secured together. The freedom of movement in at least one direction may provide sufficient strain relief for the rigid material  230  to allow it to bend along the axis A without cracking or breaking. 
     It should be noted that other rotation axes are possible other than axis A. The location of the rotation axis A may depend on the orientation of the geometric pattern  282  as well as the location of the bending force. In some embodiments, the rotation axis A may be positioned substantially anywhere along the flexible portion  204 . In other embodiments, the rotation axis may be fixed in a single position and may form a living hinge in that the material  230  such that the material  230  may only be able to rotate along that single axis. The rotation axis may be defined by the degree of movement between adjacent interlocking features. Accordingly, by restricting or reducing the movement of certain features relative to others, the flexible portion  204  may be configured to only rotate or bend along an axis that may be aligned with other features that may have increased movement relative to other interlocking features. 
     In another embodiment, sidewalls of the interlocking features may be similarly angled.  FIG. 6A  is a top plan view of another embodiment of the interlocking features for the geometric pattern  382 . In this embodiment, interlocking features  386  may be movably secured together by a neck portion  410  of the flex apertures  384 . That is, a head portion  406  of the interlocking features  386  may substantially touch laterally adjacent head portions  406  so that the neck portion  410  may be relatively narrow. 
     In these embodiments, the head portions  406  of interlocking rows may be pinched by the head portions  402  of the other row of interlocking features  386 .  FIG. 6B  is an enlarged view of a first row  398  interlocked with a second row  400 .  FIG. 6C  is an enlarged perspective view of the geometric pattern  382 . As the head portion  406  may be wider than the neck portion  410  of the flex apertures  384 , first row  398  may be substantially prevented from becoming disconnected from the second row  400 . However, the first row  398  may move in a first plane relative to the second row  400 , until the sidewalls of the first interlocking feature  386 A encounter the sidewalls of the second interlocking features  386 B defining the flex aperture  384 . For example, the sidewalls  394  may be angled as they extend from the outer surface  260  to the inner surface  262 , so that the upper portions of the sidewalls  394  may be narrower than the bottom portions of the sidewalls  394 . This may allow the top portions of the sidewalls  394  to be movable relative to adjacent interlocking features  386 , while the bottom portions of the sidewalls  394  may be secured in place. Additionally, in some embodiments, the sidewalls of the interlocking features  386  for the first row  398  may be oppositely angled from the sidewall of the interlocking features  386  for the second row  400 . 
     Further, the first interlocking feature  386 A may also move in a second plane, e.g., in the Y direction away from the plane of the rigid material  230 . In some embodiments, a portion of the first interlocking feature  386 A may be pinched within the neck portion  410  of the flex aperture  384  (due to the head portions  406  of adjacent interlocking features) such that the head portion  406  of the first interlocking feature  386 A may extend upwards or downwards relative to the second row  400  while remaining secured thereto. 
     In other embodiments, the interlocking features may bend in multiple directions and orientations.  FIG. 7A  is a bottom fragmentary perspective view of another embodiment of the geometric pattern  482  including interlocking features  502  that may bend in two directions.  FIG. 7B  is a top perspective view of the geometric pattern  482 .  FIG. 7C  is a top plan view of an interlocking feature  502 A removed from the geometric pattern  482 . In this embodiment, rows  498 ,  500  may be formed of a series of separately interlocked features  502 A,  502 B,  502 C,  502 D,  502 E. In this manner, due to the flex apertures  484  separating portions of the material  230 , the interlocking features  502  may be discrete elements movable connected together to form rows  498 ,  500 . That is, unlike the rows  298 ,  300  and rows  398 ,  400  which may include a main portion with adjacent interlocking features extending therefrom, the rows  498 ,  500  may be formed of separate interlocking features  502  movably connected together. 
     With reference to  FIG. 7C , each interlocking feature  502 A- 502 E may include a main body  510  with one more locking members extending therefrom. For example, the interlocking features  502 A- 502 E may include two legs  512 ,  514  extending from a first end of the main body  510 , a head  520  extending from a second end of the main body  510  opposite the legs  512 ,  514 , and a back portion  516  extending from a first side of the main body  510 . Also, a second side of the main body  510  may define a receiving aperture  524 . The receiving aperture  524  may include a neck portion  528  defined by two pinching members  522 ,  526  that may extend into the receiving aperture  524  at the edge of the second side of the main body  510 . A head receiving aperture  530  may be defined between the two legs  512 ,  514  of the interlocking feature  502 . 
     In some embodiments, the edges of the rigid material  230  surrounding the flexible portion  204  may define portions of the interlocking features  502 A- 502 E. In these embodiments, these portions of interlocking features  502  may operably connect to one or more other interlocking features  502 A- 502 E. Accordingly, some portions of the geometric pattern  482  may include non-discrete interlocking features. 
     With reference to  FIGS. 7A and 7C , the interlocking features  502 A- 502 E may be operably connected to one or more other interlocking features  502 A- 502 E. For example, within middle portions of the geometric pattern  482 , a first interlocking feature  502 A may be operably connected to four other interlocking features  502 B,  502 C,  502 D, and  502 E. For example, the head  520  of the interlocking feature  502 C may be received within the head receiving aperture  530  in the first interlocking feature  502 A, where the back portion  516  of the first interlocking feature  502 A may be received within the receiving aperture  524  of the second interlocking feature  502 B, the head  520  of the first interlocking feature  502 A may be received within the head receiving aperture  530  within the fourth interlocking feature  502 D, and the back portion  516  of the fifth interlocking feature  502 E may be received within the receiving aperture  524  of the first interlocking feature  502 A. Thus, the first interlocking feature  502 A may be operably connected to each of the other interlocking features  502 B,  502 C,  502 D,  502 E. 
     It should be noted that the bending radius of the rigid material or forming material may be modified by varying one or more parameters of the geometric pattern. A few parameters include, width of the flex aperture, angulation of the sidewalls boarding the flex apertures or grooves, pitch of the cuts, and thickness of the rigid material. 
     As briefly discussed above, the rigid material  230  may be used to form the enclosure  202  for the electronic device  200 .  FIG. 8A  is a perspective view of another embodiment of an electronic device  600 .  FIG. 8B  is a perspective view of the electronic device in a flexed position. In  FIGS. 8A and 8B , the electronic device  600  is an audio output mechanism such as headphones operably and electronically connected to a communication cable  603 . The communication cable  603  may be operably connected to a speaker  605  by the enclosure  602 . 
     The enclosure  602  may be formed of the rigid material  230  and may optionally be operably connected to a second portion of top of the enclosure  607 . In other embodiments, the enclosure  602  may be a substantially unitary structure, with the flexible portion  604  being located near the connection to the cable  603 . The enclosure  602 , as shown in  FIGS. 8A and 8B , may include the geometric pattern  382  of  FIGS. 6A-6C  along the length of the flexible portion  604 . This may allow the enclosure  602  to bend, while still maintaining a rigid connection to the speaker  605 . For example, the communication cable  603  may be flexible and may move relative to the enclosure  602 , which in conventional rigid enclosures may cause the enclosure to wear and/or crack over time. As the enclosure  602  may bend and flex as the communication cable  603  may move. Thus, the enclosure  602  may be substantially prevented from breaking or cracking due to the movement of the communication cable  603 . Additionally, the flexibility of the enclosure  602  may increase the bending radius of the communication cable  603  at the connection location. This may provide a strain relief for the cable  603 , which may help to prevent internal wires or the cable  603  itself from breaking due to a bending force. It should be noted that although the enclosure  602  is positioned at the end of the cable closest to the speakers, it should be noted that the enclosure may be positioned at other locations where strain relief may be desired. For example, the flexile portion of the enclosure may be positioned at a second end of the cable that may connect the cable to an electronic device (e.g., through an audio port or the like). In this example, the flexibility of the enclosure may allow the cable to remain connected to the port, but may also flex or bend. 
     Using the techniques described herein, a cover, band, or the like may be formed using a rigid or substantially rigid material.  FIG. 9A  is a top plan view of a cover for an electronic device including a geometric pattern defined therein.  FIG. 9B  is a side elevation view of the cover and the electronic device of  FIG. 9A  with the cover partially retracted.  FIG. 9C  is a top perspective view of the cover and the electronic device of  FIG. 9A  with the cover fully retracted and acting as a support or stand for the electronic device. With reference to  FIGS. 9A-9C , an electronic device  700  includes a cover  704  having the geometric pattern  282  defined therein. 
     As described above with respect to  FIG. 5C , the geometric pattern  282  may include a plurality of flex apertures  284  and interlocking features that allow the rigid material forming the cover  704  to bend or flex. In the embodiment illustrated in  FIGS. 9A-9C , the angulation of the features defined in the cover  704  allows the cover  704  to be rolled around itself. In some embodiments, the geometric pattern  282  may be substantially the same as the pattern shown in  FIG. 5C . However, in the example illustrated in  FIG. 9A , the flex apertures  284  may be defined in vertical columns that extend along a height of the computing device  702 . This configuration may allow the entire cover  704  to flex about an axis parallel to the length axis of the computing device  702 . In other words, the cover  704  may roll or flex in a direction substantially parallel to the direction of the columns of the flex apertures  284 . However, it should be noted that the geometric pattern for the cover may be selected based on a desired flex direction, bend radius, and the like. Thus, the geometric pattern and the bending direction illustrated in  FIGS. 9A-9C  are illustrative only. 
     As shown in  FIG. 9A , the cover  704  may lie substantially flat against the top surface of the computing device  702  and may protect a display  712  or other portions of the computing device  702 . With reference to  FIG. 9A , a first end  708  of the cover  704  may be rolled towards a second end  710  forming a rolled portion  706 . As the cover  704  is rolled upon itself, the display  712  or other portions of the computing device  702  may be exposed. 
     In some embodiments, with reference to  FIG. 9C , the cover  704  may be configured to roll and wrap around an edge of the computing device  702  to act as a support stand. For example, a portion of the computing device  702  may rest on the rolled portion  706  of the cover  704 , which may allow the computing device  702  to be supported above a surface at a support angle  714 . The support angle  714  may generally correspond to the outermost radius of the bend portion  706 . In other words, the radial bend of the cover  704  may be defined by geometric pattern, the angulation of the sidewalls defining the flex apertures and the features. 
     With continued reference to  FIG. 9C , the second end  710  of the cover  704  may be anchored to an edge  716  of the computing device  702  and may rotate about the edge  716 , allowing the rolled portion  706  of the cover  704  to rotate around the edge  716  to a backside of the computing device  702 . 
     CONCLUSION 
     The foregoing description has broad application. For example, while examples disclosed herein may focus on enclosures, it should be appreciated that the concepts disclosed herein may equally apply to substantially any other components constructed out of rigid materials, such as, but not limited to, garage doors, coverings for architectural openings (e.g., blinds or shades), bands for supporting an electronic device around a portion of a user, and so on. Moreover, although the discussion is made with respect to rigid materials, the methods and techniques may be applied to a variety of materials where an increased flexibility or a flexible portion is desired. Accordingly, the discussion of any embodiment is meant only to be exemplary and is not intended to suggest that the scope of the disclosure, including the claims, is limited to these examples.

Metadata:
Filing Date: 20170710
Publication Date: 20200114
Grant Date: 20200114
Priority Date: 20120216
Inventors: RUSSELL-CLARKE, Peter N.
NASHNER, MICHAEL S.
Assignee: APPLE INC
CPC Classifications: [{"code": "E05D1/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "B21D31/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C53/063", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C53/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1616", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C53/063", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/13", "inventive": false, "first": false, "tree": "[]"}, {"code": "B21D31/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1616", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/13", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D85/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K26/38", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1613", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C53/063", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1616", "inventive": true, "first": false, "tree": "[]"}, {"code": "B21D31/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K26/38", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T428/13", "inventive": false, "first": false, "tree": "[]"}, {"code": "B65D85/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "B21D31/04", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 47843399