PATENT DOCUMENT

Publication Number: US-8564961-B2
Application Number: US-23585708-A
Country: US
Kind Code: B2

Title: Methods and apparatus for providing holes through portions of a housing of an electronic device

Abstract:
Electronic devices are provided with housing components that have improved aesthetics. One or more holes may be formed through an extruded portion of the housing.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a hollow housing having a central cavity; 
 a light source component positioned within the central cavity; and 
 a front wall having a front surface corresponding to a front surface of the electronic device, the front wall comprising:
 an opening having a size and shape defined by a plurality of edges of the front wall, the opening suitable for securing a display component at at least one of the plurality of edges adjacent to the display component, and 
 at least one hole disposed within the front wall such that at least a portion of the hole has a parallel orientation with respect to the front surface, the at least one hole having a first end positioned at the one of the plurality of edges used to secure the display component and a second end positioned proximate to the light source component, the hole allowing light from the light source component entering at the second end to pass through and exit the first end adjacent the display component. 
 
 
     
     
       2. The electronic device as recited in  claim 1 , wherein the hollow housing includes four extruded side walls. 
     
     
       3. The electronic device as recited in  claim 1 , wherein an external surface of the hollow housing comprises a ceramic material. 
     
     
       4. The electronic device as recited in  claim 3 , wherein the ceramic material is at least one of alumina and zirconia. 
     
     
       5. The electronic device as recited in  claim 1 , wherein the hollow housing comprises a metal material. 
     
     
       6. The electronic device as recited in  claim 1 , wherein light exiting the first end at the display component acts as a back light for the display component. 
     
     
       7. The electronic device as recited in  claim 1 , wherein the hole is disposed within the front wall on an axis that is substantially parallel to an external surface of the front wall. 
     
     
       8. The electronic device as recited in  claim 1 , wherein the front wall comprises a plurality of holes, each hole allowing light from the light source component to pass therethrough and exit at the display component. 
     
     
       9. A housing for an electronic device, comprising:
 a central cavity suitable for carrying a light-generating component; and 
 a front wall having a front surface corresponding to a front surface of the electronic device, comprising:
 an opening having a size and shape defined by a plurality of edges of the front wall, the opening suitable for securing a display component to the front wall at one of the plurality of edges adjacent to the display component; and 
 at least one hole disposed within the front wall such that at least a portion of the hole has a parallel orientation with respect to the front surface, the at least one hole having a first end positioned at the one of the plurality of edges used to secure the display component and a second end positioned proximate to the light-generating component, the hole allowing light from the light-generating component entering the second end to pass through and exit the first end adjacent the display component. 
 
 
     
     
       10. The housing as recited in  claim 9 , wherein light exiting the first end at the display component acts as a backlight for the display component. 
     
     
       11. The housing as recited in  claim 9 , wherein the front wall comprises a plurality of holes, each hole allowing light from the light-generating component to pass therethrough and exit at the display component. 
     
     
       12. The housing as recited in  claim 11 , wherein a plurality of first ends associated with the plurality of holes is arranged in a pattern at the one of the plurality of edges adjacent to the display component, wherein the plurality of first ends are equidistant to each other in the pattern. 
     
     
       13. The housing as recited in  claim 9 , wherein hole is disposed within the front wall on an axis that is substantially parallel to an external surface of the front wall. 
     
     
       14. The housing as recited in  claim 9 , wherein the front wall is comprised of metal and the at least one hole is disposed within the metal. 
     
     
       15. An electronic device, comprising:
 a housing having a front wall and a central cavity; 
 a light-generating component housed within the central cavity of the housing; 
 a display component; 
 an opening in the front wall having a plurality of edges configured to secure the display component within the opening; 
 a plurality of holes disposed within the a front wall of the housing, the plurality of holes extending longitudinally through the front wall, wherein at least one of the plurality of holes has a first end positioned at one of the plurality of edges adjacent to the display component and a second end positioned proximate to the light-generating component, wherein the at least one hole allows light from the light-generating component entering at the second end to pass through and exit at the first end adjacent to the display component. 
 
     
     
       16. The electronic device as recited in  claim 15 , wherein a second of the plurality of holes has a beginning end positioned at a signal-generating component housed within the external housing and a final end positioned at one of the plurality of edges of the opening, the electronic device further comprising:
 a wire disposed within the second hole from the beginning end to the final end, wherein the wire allows a signal from the signal-generating component to pass through the second hole to the display component. 
 
     
     
       17. The electronic device as recited in  claim 16 , wherein the signal-generating component is a power source configured to provide power to the display component. 
     
     
       18. The electronic device as recited in  claim 15 , wherein light exiting the first end at the display component acts as a backlight for the display component. 
     
     
       19. The electronic device as recited in  claim 15 , wherein the front wall has an exterior surface corresponding to a front exterior surface of the electronic device. 
     
     
       20. The electronic device as recited in  claim 19 , wherein the hole is disposed on an axis that is substantially parallel to the exterior surface of the front wall.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This claims the benefit of U.S. Provisional Patent Application No. 61/004,848, filed Nov. 30, 2007, and U.S. Provisional Patent Application No. 61/025,531, filed Feb. 1, 2008, each of which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This relates to methods and apparatus for providing holes through housing components and other external surfaces of electronic devices. 
     BACKGROUND OF THE DISCLOSURE 
     There is a need for constructing holes through housing components and other external surfaces of various electronic devices. Specifically, there is a need for improving the aesthetics, size, and ease of manufacture of such holes. 
     Some known electronic devices (e.g., computers and telephones) include at least one internal electronic component associated with the operation of the device and a protective housing that at least partially encloses the internal electronic component. Typically, the housing includes one or more housing components that serve to at least partially surround the internal electronic components at a peripheral region of the electronic device so as to cover and protect the internal components from adverse conditions. Also, one or more holes may be provided through one or more of the housing components. Information transmitted from and/or received by the internal electronic components may be passed through the one or more holes provided through the housing component of the electronic device. Some known housing components include openings that at least partially expose external surfaces of internal electronic components. One or more holes may also be provided through exposed external surfaces of electronic components. 
     Cosmetic features are important to consumers of electronic devices, as these features help create the overall impression that one has of the electronic device. Therefore, the housing components, other external surfaces, and the holes provided therethrough, may also be configured to form and aesthetically enhance the outward appearance of the electronic device. For example, the shape, contours, and/or color of the housing and/or the holes provided through the housing may be designed so as to create a positive impression about the electronic device, thereby contributing to the overall success of the device in the market place. 
     Accordingly, what is needed are apparatus and methods for providing holes through housing components and other external surfaces of electronic devices that are aesthetically pleasing, small, and easy to manufacture. 
     SUMMARY OF THE DISCLOSURE 
     Apparatus and methods for providing holes through housing components and other external surfaces of electronic devices that are aesthetically pleasing, small, and easy to manufacture are provided. 
     According to one embodiment of the invention, there is provided a method of forming an external surface portion of an electronic device. The method may include extruding a block of material longitudinally for creating at least one hole through the material and assembling the external surface portion using at least a portion of the extruded block that has at least a portion of the at least one hole therethrough. The at least a portion of the at least one hole may provide at least one passageway for information to be communicated through the extruded block. 
     According to another embodiment of the invention, there is provided an electronic device including an extruded external surface portion that may include an inner surface, an outer surface, and at least one hole formed between the inner surface and the outer surface. The electronic device may also include an input/output interface component adjacent the inner surface. The at least one hole may provide at least one passageway for information to be communicated through the extruded external surface portion between the interface component and an environment adjacent the outer surface. 
     According to another embodiment of the invention, there is provided an electronic device including a housing component that may include an inner surface, an outer surface, and at least one hole extruded between the inner surface and the outer surface. The electronic device may also include an input/output interface component, wherein the at least one hole provides at least one passageway for information to be communicated through the housing component between the interface component and an environment adjacent the outer surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the invention, its nature, and various advantages will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1  is a top, front, right perspective view of an electronic device in accordance with some embodiments of the invention; 
         FIG. 2  is a top elevational view of a portion of the electronic device of  FIG. 1 ; 
         FIG. 3  is a cross-sectional view of a portion of the electronic device of  FIGS. 1 and 2 , taken from line III-III of  FIG. 2 ; 
         FIG. 4  is a cross-sectional view of a portion of the electronic device of  FIGS. 1-3 , similar to  FIG. 3 , but with an additional component, in accordance with some embodiments of the invention; 
         FIG. 5  is a top elevational view, similar to  FIG. 2 , of an extruded portion of an electronic device in accordance with some embodiments of the invention; 
         FIG. 5A  is a cross-sectional view of the extruded portion of  FIG. 5 , taken from line VA-VA of  FIG. 5 , before a process in accordance with some embodiments of the invention; 
         FIG. 5B  is a cross-sectional view of the extruded portion of  FIGS. 5 and 5A , similar to  FIG. 5A , but after a process in accordance with some embodiments of the invention; 
         FIG. 6  is a diagram of a system for forming an extruded portion of an electronic device in accordance with some embodiments of the invention; 
         FIG. 7  is a diagram of a system for forming an extruded portion of an electronic device in accordance with some other embodiments of the invention; and 
         FIG. 8  is a flowchart of an illustrative process for forming a portion of an electronic device in accordance with some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Apparatus and methods are provided for providing holes through housing components and other external surfaces of electronic devices that are aesthetically pleasing, small, and easy to manufacture. The invention will now be described with reference to  FIGS. 1-8 . 
       FIGS. 1-4  show an embodiment of electronic device  100  including at least one external surface portion constructed in accordance with the invention. The term “electronic device” can include, but is not limited to, music players, video players, still image players, game players, other media players, music recorders, video recorders, cameras, other media recorders, radios, medical equipment, domestic appliances, transportation vehicle instruments, calculators, cellular telephones, other wireless communication devices, personal digital assistants, programmable remote controls, pagers, laptop computers, desktop computers, printers, and combinations thereof. In some cases, the electronic devices may perform a single function (e.g., a device dedicated to playing music) and, in other cases, the electronic devices may perform multiple functions (e.g., a device that plays music, displays video, stores pictures, and receives and transmits telephone calls). 
     Moreover, in some cases, these electronic devices may be any portable, mobile, hand-held, or miniature electronic device having at least one external surface portion constructed in accordance with the invention so as to allow a user to use the device wherever the user travels. Miniature electronic devices may have a form factor that is smaller than that of hand-held electronic devices, such as an iPodTM available by Apple Inc. of Cupertino, Calif. Illustrative miniature electronic devices can be integrated into various objects that include, but are not limited to, watches, rings, necklaces, belts, accessories for belts, headsets, accessories for shoes, virtual reality devices, other wearable electronics, accessories for sporting equipment, accessories for fitness equipment, key chains, and combinations thereof. Alternatively, electronic devices that include an external surface portion constructed in accordance with the invention may not be portable at all, but may instead be generally stationary, such as a television or a desktop computer (e.g., an iMacTM available by Apple Inc.). 
     Electronic device  100  can include at least one electronic component (e.g., a processor, memory region, display component, transmitter, receiver, etc.) and a protective housing (e.g., housing  101 ) that at least partially encloses the one or more electronic components of the device. As shown in  FIG. 1 , for example, housing  101  of device  100  may at least partially enclose a device output component  197  (e.g., a video display screen) and a user input component  199  (e.g., a scroll wheel). Moreover, as shown in  FIG. 1 , housing  101  can be hexahedral. Although, it should be noted that housing  101  of device  100  is only exemplary and need not be substantially hexahedral, and that, in certain embodiments, the housing of device  100  could generally be formed in any other suitable shape, including, but not limited to, substantially spherical, ellipsoidal, conoidal, octahedral, or a combination thereof, for example. 
     In some embodiments, housing  101  may include one or more housing components. Each of the housing components may be made from the same type of material or from various different types of materials including, but not limited to, metal (e.g., aluminum, titanium, steel, copper, etc.), plastic (e.g., polycarbonate, ABS, nylon, etc.), ceramic (e.g., alumina, zirconia, etc.), or combinations thereof, such as that described in Zadesky et al., U.S. Published Patent Application No. 2006/0268528, published Nov. 30, 2006, and Zadesky et al., U.S. Published Patent Application No. 2008/0165485, published Jul. 10, 2008, each of which is hereby incorporated by reference herein in its entirety. Each housing component may be coupled to another housing component in various ways including, but not limited to, adhesives, screws, snap-fits, welding, integrally, and the like. 
     In some embodiments, housing  101  may include at least one housing component formed from metal. The metal housing component may be configured to make the electronic device look as if the electronic device was formed from a single block of metal (i.e., a solid piece of metal that has been hollowed out). 
     In other embodiments, however, housing  101  may not be formed from a block of material, as the cost of doing this can be quite expensive. That is, although the housing component may look as though it was machined to give it its net shape from a single block of material, it may in fact be formed by other processes designed to mimic the machined look. 
     In some embodiments, a metal housing component that looks like it was formed from a block of material may be formed rather from a piece of sheet of metal (e.g., flat stock). That is, the sheet metal may be formed in such a way that the final part looks like it was machined down from a large thick slab of material. By utilizing sheet metal, the overall cost of the part can be reduced (e.g., it is very expensive to machine down a large piece of metal as it wastes a lot of material and time). 
     In some embodiments, the shape of the housing component may be at least partially created by drawing and, more particularly, by deep drawing portions of the sheet of metal. Additionally or alternatively, the shape of the housing component may be at least partially created by forging portions of the sheet of metal. Additionally or alternatively, the shape of the housing component may be at least partially created by machining portions of the sheet of metal. For example, a sheet of metal may be deep drawn to form a housing component with a front wall and side walls extending therefrom (e.g., to form a box or can with one open end). The housing component may be configured with a front wall and top, right side, left side, and bottom walls at the peripheral edge portions of the front wall. The front wall as well as the other walls may include various openings for exposing external surfaces of input/output (“I/O”) components associated with the electronic device. For example, the front wall may include a large opening for exposing an external portion of a display of the electronic device (e.g., device output component  197 ) and another opening for exposing an external portion of a scroll wheel of the electronic device (e.g., user input component  199 ). Thereafter, portions of the housing component may be forged to affect its geometry at specific locations (e.g., to change the shape and/or thickness of the material at specific locations). Thereafter, portions of the housing component may be machined to form a near net shape. 
     Any portion or the entirety of any housing component or any portion of any external surface of an electronic device may include one or more holes formed therethrough for providing an I/O interface, such as that described in Andre et al., U.S. Published Patent Application No. 2008/0084404, published Apr. 10, 2008, and Andre et al., U.S. Published Patent Application No. 2008/0024470, published Jan. 31, 2008, each of which is hereby incorporated by reference herein in its entirety. 
     Alternatively or additionally, in accordance with the invention, any portion of or the entirety of any housing component and/or any portion of any electronic component exposed by an opening in a housing component may be extruded to provide one or more small holes therethrough according to the invention. For example, in some embodiments, such holes may provide passageways for information to be communicated through the extruded portion to and/or from one or more electronic components disposed within the housing of the device (e.g., an I/O interface component). An I/O component may be positioned adjacent the inner surface of an extruded portion of a housing component and under one or more of the extruded holes, thereby creating an I/O interface. Alternatively, one or more holes may be provided through an external portion of an I/O component itself, thereby creating an I/O interface. Such holes may be extruded to create passageways for various types of information for various I/O components, including, but not limited to, sound to a microphone or from a speaker, light to a light sensor or from a visual indicator, and the like. Additionally or alternatively, such holes may be extruded to give a user of the device access to various features or components internal to electronic device  100 , such as buttons, switches, connectors, and the like. 
     For example, as shown in  FIGS. 1-4 , an external portion  103  of electronic device  100  may be extruded to provide one or more holes  150  therethrough. Although extruded portion  103  is described with respect to  FIGS. 1-4  as an external portion provided in a cavity along a top wall of housing component  120  of housing  101 , it is to be understood that extruded portion  103  may be any portion of or the entirety of any housing component of electronic device  100 . Alternatively, extruded portion  103  may be any other external portion of electronic device  100  (e.g., an outer surface portion of a click wheel or any other I/O component) in accordance with the invention. For example, an extruded portion of the invention, such as extruded portion  103 , may be provided as an entire wall or as multiple walls of a housing of electronic device  100 . 
     As shown in  FIGS. 2-4 , for example, a cavity  110  may be formed between a “cosmetic” or outer surface  122  and an opposite or “internal” or inner surface  124  of housing component  120  of housing  101 . Cavity  110  may be defined by an outer opening  112  in outer surface  122  of housing component  120 , an inner opening  114  in inner surface  124  of housing component  120 , and a hollow passageway  116  extending therebetween. Cavity  110  may be formed through housing component  120  at the location where extruded portion  103  is to be provided. Cavity  110  may be formed by any suitable process, such as laser ablating, for example. 
     Similarly, each hole  150  may be provided between a “cosmetic” or outer surface  102  and an opposite or “internal” or inner surface  104  of extruded portion  103 . Two or more holes  150  may form a collection or pattern  158  of neighboring holes  150  on outer surface  102  of extruded portion  103 . Each hole  150  may be defined by an outer opening  152  in outer surface  102  of extruded portion  103 , an inner opening  154  in inner surface  104  of extruded portion  103 , and a hollow passageway  156  extending therebetween. Portion  103  may be formed by any suitable extrusion process, as described below in more detail, for example. 
     In some embodiments, one or more holes  150  may be formed by creating a hollow passageway in extruded portion  103  between an outer opening in outer surface  102  and an inner opening in inner surface  104  such that substantially all sides of the passageway are parallel with one another. Moreover, the sides of the passageway may also be parallel with an axis that is substantially perpendicular to outer surface  102 , and, in some embodiments, substantially in the center of outer surface  102 . For example, as shown in  FIGS. 2 and 3 , the walls of each of hollow passageways  156  in extruded portion  103  between outer opening  152  in outer surface  102  and inner opening  154  in inner surface  104  may be substantially parallel with an axis A that is substantially perpendicular to outer surface  102 . In other embodiments, one or more holes may be formed by creating a tapered hollow passageway in portion  103  between outer surface  102  and inner surface  104  such that one or more side portions of the passageway are angled with respect to each other. Moreover, one or more side portions of the passageway may be angled with respect to an axis that is substantially perpendicular to outer surface  102  (e.g., axis A). 
     Although shown greatly enlarged in  FIGS. 2-4 , one or more of holes  150  may be imperceptible or invisible to the unaided human eye. That is, the cross-sectional area of outer opening  152  of one or more holes  150  may be too small to be resolvable by a user looking at outer surface  102  of extruded portion  103 . The average limit of resolution for the unaided adult human eye is about 0.10 millimeters at a viewing distance of about 1 meter. For children, the average limit of resolution is somewhat finer (e.g., 0.04 millimeters at a viewing distance of about 1 meter). Therefore, depending on the anticipated viewer  190  and the anticipated viewing distance V between his or her eye  192  and outer surface  102  of extruded portion  103  (see, e.g.,  FIG. 3 ), the cross-sectional area of outer opening  152  of one or more holes  150  may be selected to be below the limit of resolution of user  190 , thereby being imperceptible or invisible to user&#39;s eye  192  (see, e.g.,  FIG. 3 ). 
     For example, in some embodiments, the cross-sectional area of outer opening  152  of one or more holes  150  may be in the range of 175 square micrometers to 1600 square micrometers. In some embodiments, the cross-sectional area of outer opening  152  of one or more holes  150  may be in the range of 300 square micrometers to 1250 square micrometers. In some embodiments, the cross-sectional area of outer opening  152  of one or more holes  150  may be in the range of 500 square micrometers to 1000 square micrometers. In some embodiments, the cross-sectional area of outer opening  152  of one or more holes  150  may be about 750 square micrometers. In other embodiments, the cross-sectional area of outer opening  152  of one or more holes  150  may be much larger or much smaller. As a more specific example, if outer opening  152  is provided as a circular opening having a diameter d, as shown, diameter d of outer opening  152  of one or more holes  150  may be in the range of 15 micrometers to 45 micrometers. In some embodiments, the diameter d of outer opening  152  of one or more holes  150  may be in the range of 20 micrometers to 40 micrometers. In some embodiments, the diameter d of outer opening  152  of one or more holes  150  may be in the range of 25 micrometers to 35 micrometers. In some embodiments, the diameter d of outer opening  152  of one or more holes  150  may be about 30 micrometers. In other embodiments, the cross-sectional area of outer opening  152  of one or more holes  150  may be much larger or much smaller. 
     Thus, as defined herein, the term “invisible hole” and/or “micro hole” may refer to any hole with an outer opening that is smaller than what may be resolvable by an unaided human eye at an anticipated viewing distance. Conversely, it is to be understood that the terms “visible hole” and/or “macro hole,” as defined herein, may refer to any hole with an outer opening that is large enough to be resolvable by an unaided human eye at an anticipated viewing distance. 
     Extruded portion  103  of electronic device  100  may be made of any suitable material that may be extruded and retain its structural integrity. For example, extruded portion  103  may be made of one or more various types of materials, such as metals, metal alloys, plastics, ceramics, and the like. By way of example, the metals may correspond to aluminum, titanium, steel, copper, etc., the plastic materials may correspond to polycarbonate, ABS, nylon, etc., and the ceramic materials may correspond to alumina, zirconia, etc., and combinations thereof. 
     Once formed, extruded portion  103  may be assembled into cavity  110  of housing component  120 . In some embodiments, extruded portion  103  and cavity  110  may be formed such that, when assembled, outer surface  102  of extruded portion  103  fills outer opening  112  of cavity  110  and appears substantially continuous with outer surface  122  of housing component  120 . Extruded portion  103  may be retained within cavity  110  in many various ways including, for example, an adhering substance or mechanical holding elements (not shown). Alternatively, extruded portion  103  and cavity  110  may be formed such that, when assembled, outer surface  102  of extruded portion  103  extends above or is recessed below outer opening  112  of cavity  110 . In yet other embodiments, extruded portion  103  and cavity  110  may be formed such that, when assembled, inner surface  104  of extruded portion  103  fills outer opening  112  of cavity  110  and appears substantially on top of outer surface  122  of housing component  120 . It is to be understood that extruded portion  103  may be assembled in any suitable way with respect to a cavity formed in any location of any component of any electronic device in accordance with the invention. In some embodiments, extruded portion  103  may be the entire housing  101  itself, depending on the needs of device  100 . 
     Housing component  120  (or any other component of electronic device  100  that may be provided with an extruded portion, such as an external surface portion of a scroll wheel) may be provided with an overall thickness T between outer surface  122  and inner surface  124 . In some embodiments, thickness T may be in the range of 0.5 millimeters to 5.5 millimeters. In some embodiments, thickness T may be in the range of 1.5 millimeters to 4.5 millimeters. In some embodiments, thickness T may be in the range of 2.5 millimeters to 3.5 millimeters. In some embodiments, thickness T may be about 3.0 millimeters. In other embodiments, thickness T may be in the range of 0.25 millimeters to 0.75 millimeters. In some embodiments, thickness T may be in the range of 0.35 millimeters to 0.65 millimeters. In some embodiments, thickness T may be in the range of 0.45 millimeters to 0.55 millimeters. In some embodiments, thickness T may be about 0.49 millimeters. 
     Extruded portion  103  may be provided with an overall thickness t between outer surface  102  and inner surface  104  that may be similar to thickness T of housing component  120 . However, in some embodiments, as shown in  FIG. 3 , for example, extruded portion  103  may be provided with an overall thickness t between outer surface  102  and inner surface  104  that is smaller than thickness T of housing component  120 . As shown in  FIG. 3 , for example, extruded portion  103  may have a reduced thickness t with respect to thickness T of housing component  120  such that a portion of cavity  110  may not contain extruded portion  103  (e.g., the portion of cavity  110  between inner surface  124  of housing component  120  and inner surface  104  of extruded portion  103 ). In some embodiments, thickness t may be in the range of 0.2 millimeters to 0.8 millimeters. In some embodiments, reduced thickness t may be in the range of 0.3 millimeters to 0.7 millimeters. In some embodiments, reduced thickness t may be in the range of 0.4 millimeters to 0.6 millimeters. In some embodiments, reduced thickness t may be about 0.5 millimeters. In other embodiments, reduced thickness t may be in the range of 0.05 millimeters to 0.45 millimeters. In some embodiments, reduced thickness t may be in the range of 0.15 millimeters to 0.35 millimeters. In some embodiments, reduced thickness t may be about 0.25 millimeters. 
     An I/O interface component may be provided adjacent the inner surface of the extruded portion under one or more holes provided therein for creating an I/O interface. As shown in  FIG. 4 , for example, an I/O component  170  may be provided adjacent inner surface  104  of extruded portion  103 . In some embodiments, I/O component  170  may be positioned such that an outer surface  172  of I/O component  170  faces an inner opening  154  of one or more holes  150  in extruded portion  103 . If the respective thicknesses t and T of extruded portion  103  and housing component  120  provide a vacant portion of cavity  110 , that vacant portion of cavity  110  may be sized such that I/O component  170  fits therein. It is to be understood that extruded portion  103  may be a portion of an I/O component  170  in accordance with the invention. For example, extruded portion  103  may be an external surface portion of a scroll wheel I/O component  170 . 
     I/O component  170  may be any component suitable for transmitting and/or receiving information through one or more holes  150  proximal thereto. A minimum aspect ratio of the total cross-sectional area of the openings of holes  150  formed through extruded portion  103  with respect to the total cross-sectional area or surface area of the active portion of I/O component  170  may be carefully designed to meet the performance specifications of that particular I/O component. 
     For example, in some embodiments, I/O component  170  may be a microphone that is capable of receiving sound waves transmitted from a source external to the housing component (e.g., external source  180 ) through one or more holes  150 . The minimum aspect ratio of the combined total cross-sectional area of outer openings  152  of holes  150  with respect to the total surface area of the active portion of microphone I/O component  170  (e.g., the total surface area of the transducer or sensor used to receive sound waves) may be chosen to meet specific performance requirements of microphone  170 . In some embodiments, this minimum aspect ratio may be in the range of 10% to 30%. In some embodiments, this minimum aspect ratio may be in the range of 15% to 25%. In some embodiments, this minimum aspect ratio may be about 18.4%. 
     As shown in  FIG. 4 , for example, I/O component  170  may include an active portion  175  that spans outer surface  172 . Moreover, as shown in  FIG. 4 , active portion  175  and outer surface  172  of I/O component  170  may also span inner surface  104  of extruded portion  103 . In this embodiment, in which holes  150  may be utilized to pass sound waves from external source  180  to I/O component  170  configured as a microphone, each hole  150  may be provided with a circular outer opening  152  having a diameter d (see, e.g.,  FIGS. 2-4 ), for example. Moreover, cavity  110  may be formed within housing component  120  as a cylinder having a diameter D (see, e.g.,  FIGS. 2-4 ) and, therefore, inner surface  104  of extruded portion  103  and active portion  175  of microphone  170  may also be cylindrical with a diameter D. 
     In this particular illustrative embodiment, seven equally shaped holes  150  have been provided through extruded portion  103  as pattern  158 . Therefore, in order to meet specific performance specifications of microphone  170 , the combined cross-sectional area of all seven holes  150  in pattern  158  must be at least a specifically chosen percentage of the surface area of active portion  175  (i.e., have a specifically chosen aspect ratio). For example, in some embodiments, if diameter D of active portion  175  is 1.5 millimeters and if the minimum required aspect ratio of microphone  170  is 18.4%, each of the seven holes  150  of pattern  158  may be formed with an outer opening  152  having a diameter d equal to about 0.25 millimeters. 
     In other embodiments, I/O component  170  may include one or more light sources capable of transmitting light through one or more holes  150  towards a user or other entity external to the housing component (e.g., viewer  190  of  FIG. 3 ). Additionally or alternatively, I/O component  170  may include one or more receptors that may be sensitive to visible light received through one or more holes  150  from an entity external to the housing component for providing ambient light sensing (“ALS”), for example. I/O component  170  may include one or more receptors that may be sensitive to infra-red light (“IR”) received through one or more holes  150  from an entity external to the housing component for receiving IR control signals from a remote control transmitter, for example. I/O component  170  may also be configured as an antenna, a proximity detector, a motion detector, or any other suitable I/O device that may transmit and/or receive information via one or more holes  150 . 
     It is to be understood, that the foregoing is just illustrative, and that I/O component active portion  175 , cavity  110 , pattern  158 , and each one of holes  150  and its openings  152  and  154  may be formed of any suitable size and shape, including, but not limited to, triangular, rectangular, elliptical, asymmetrical, etc. Moreover, pattern  158  may be formed of any suitable number of holes  150 , including just one hole, for example. Each hole  150  in pattern  158  may be separated from other holes  150  in pattern  158  by any suitable distance, depending on the size of pattern  158  and the function of holes  150  with respect to an associated I/O component  170 . 
     For example, in some embodiments, holes extruded through a portion of an electronic device may individually create or combine to create an image. As used herein, the word “image” may refer broadly to any visual form, representation, or depiction. An image may mean and include a logo, an icon, or any other graphic representation (e.g., words, numbers, letters, figures, symbols, etc.). For example, an extruded portion of the invention may be provided adjacent or as a part of an I/O component of an electronic device. The holes of the extruded portion may provide images in the form of icons associated with functions of the electronic device (e.g., recording and playback functions of a media player electronic device). The icons may include icons representing functions such as “pause,” “play,” “stop,” “fast forward,” “reverse,” etc. 
     For example, as shown in  FIG. 5 , an extruded portion  203  similar to extruded portion  103  according to other embodiments of the invention may have an outer surface  202  that is circular. Extruded portion  203  may include various types of holes  250  of various shapes, sizes, and patterns provided for various purposes. For example, extruded portion  203  may include a plurality of holes, such as a set of small circular holes  250 - 1 , that may form an image, such as the symbol “&lt;”. Extruded portion  203  may be provided as an external surface portion of a scroll wheel I/O component of an electronic device (see, e.g.,  FIG. 1 ) and the symbol “&lt;” of holes  250 - 1  may represent a “reverse” function of the scroll wheel. Holes  250 - 1  may be “visible holes” so that the “&lt;” may be resolvable by a user of the device. Alternatively or additionally, extruded portion  203  may include a large triangular hole  250 - 2 , holes  250 - 3  that form a “&gt;” image, holes  250 - 4  that form an image reading “MENU,” and a circular hole  250 - 5 , thereby completing scroll wheel user input device  199  of device  100  of  FIG. 1 , for example. 
     Each hole  150  or  250  may be formed through an extruded portion of an electronic device using one or more suitable extrusion techniques. Generally, extrusion is a shaping process where a continuous work piece is produced by forcing material (e.g., molten or hot material) through a shaped orifice, such that the extrusion process may produce a length of a particular cross-sectional shape. The cross-sectional length or shape of the continuous work piece may be controlled at least in part on the shaped orifice. As the shaped work piece exits the orifice, it may be cooled and thereafter cut to a desired length. An extrusion process may be a continuous high volume process that can produce intricate profiles and that can accurately control work piece dimensions, such as that described in Zadesky et al., U.S. Published Patent Application No. 2006/0268528, published Nov. 30, 2006, which is incorporated by reference herein in its entirety. Furthermore, because extrusion may have low tooling costs, it may be relatively inexpensive when compared to other forming or manufacturing processes. For example, as shown in  FIG. 6 , a block of material  600  may be extruded by being drawn through a die  630  of a desired shape along a longitudinal axis A′. Die  630  may be designed to include one or more extrusion elements  640  that may extrude one or more holes  650  through the length of block  600 . In some embodiments, extrusion elements  640  may be of various sizes and patterns to create various holes  650  through block  600 , such as a single extrusion element  640 ′ that may create a single large oval hole  650 ′ that may be visible to a user, as well as multiple sets of extrusion elements  640 ″ that may create multiple sets of small circular holes  650 ″ that may be invisible to a user&#39;s naked eye. 
     Once block  600  has been extruded by die  630 , one or more extruded portions  603  may be removed from block  600  and may be provided as a portion of an electronic device in accordance with the invention. For example, a portion  603  may be cut from block  600  substantially perpendicularly from axis A′ to have a thickness t, as shown in  FIG. 6 . Therefore, more than one extruded portion  603  may be removed from block  600  and used to provide holes through an external surface portion of an electronic device in accordance with the invention. 
     Although extruded portion  103  has been described with respect to  FIGS. 1-4  as an external portion provided in a cavity along a top wall of housing component  120  of housing  101 , and although extruded portion  203  has been described with respect to  FIGS. 1 and 5  as an external surface portion of a scroll wheel I/O component of electronic device  100 , it is to be understood that extruded portion  603  may be any portion of or the entirety of any housing component or other external surface portion of electronic device  100 . For example, as shown in  FIG. 1 , extruded portion  603  may be provided as the entire right side wall of housing  101  of electronic device  100 . 
     In other embodiments, an extruded portion having one or more holes therethrough may be provided as multiple walls of a housing component of an electronic. For example, as shown in  FIG. 7 , a block of material  700  may be extruded by being drawn through a die  730  of a desired shape along a longitudinal axis A″. Die  730  may be designed to include one or more extrusion elements  740  that may extrude one or more holes  750  through the length of block  700 . In some embodiments, extrusion elements  740  may be of various sizes and patterns to create various holes  750  through block  700 , such as a single extrusion element  740 ′ that may create a single large rectangular hole  750 ′, as well as multiple extrusion elements  740 ″ that may create multiple smaller holes  750 ″ about larger hole  750 ′. 
     In some embodiments, once block  700  has been extruded by die  730 , one or more extruded portions may be removed from block  700  and may be provided as a portion of an electronic device in accordance with the invention. However, in other embodiments, as shown in  FIG. 7 , the entire extruded block  700  may be used to provide a hollow housing component with four sidewalls. For example, larger extruded hole  750 ′ may provide a large hollow throughout extruded block  700 , which may be used to contain one or more internal electronic components of an electronic device (e.g., electronic device  100 ). Therefore, a hole through an extruded electronic device portion of the invention may be used not only to pass information between an electronic component of an electronic device and an entity external to the device, but such an extruded hole may additionally or alternatively contain one or more components of an electronic device. 
     Moreover, in some embodiments, an opening  760  may be formed (e.g., machined) through one wall of extruded block  700 , such as front wall  724 . Opening  760  may be similar to the opening provided through housing  101  of electronic device  100  for exposing output device  197 , for example. As shown in  FIG. 7 , opening  760  may also expose at least some of smaller extruded holes  750 ″. In some embodiments, a smaller extruded hole  750 ″ may, for example, be used to pass light or other information from one portion of an electronic device to another portion of the electronic device. For example, light may be passed from one end of block  700  and through a smaller extruded hole  750 ″ into opening  760 . If an electronic component, such as a display output component  197 , is provided at least partially within opening  760 , then the light carried by a smaller extruded hole  750 ″ may be used to backlight the display output component, for example. Therefore, a hole through an extruded electronic device portion of the invention may be used not only to pass information between an electronic component of an electronic device and an entity external to the device, but may additionally or alternatively pass information (e.g., light) between various components of an electronic device (e.g., between a light source and a display output component). 
     Furthermore, in some embodiments, a smaller extruded hole  750 ″ may, for example, be used to carry traces, wires, or other electronic components from one portion of an electronic device to another portion of the electronic device. For example, wires may run from one end of block  700 , through a smaller extruded hole  750 ″, and into opening  760 . If an electronic component, such as a display output component  197 , is provided at least partially within opening  760 , then one or more wires may exit a smaller extruded hole  750 ″ and may connect with the electronic component within opening  760 . Therefore, a hole through an extruded electronic device portion of the invention may be used not only to pass information between an electronic component of an electronic device and an entity external to the device, but may additionally or alternatively house and carry a first electronic component (e.g., wires) between various other components of an electronic device (e.g., a power source and a display output component). 
       FIG. 8  shows an illustrative process for extruding a portion of material for use with an electronic device in accordance with the invention. Process  800  of  FIG. 8  may begin by extruding a block of material (e.g., longitudinally) to create at least one hole therethrough at step  802 . The size, shape, and/or pattern of each of the one or more holes created at step  802  may be based on the functionality of the extruded portion with respect to the electronic device (e.g., based on the type of I/O component to be provided adjacent the extruded portion for communicating information through the one or more holes of the extruded portion). 
     Next, at step  804 , the extruded block may be cut to remove a portion of the block that includes at least a portion of at least one of the one or more holes, such that the portion of the at least one hole provides at least one passageway for information to be communicated therethrough. In some embodiments, the extruded block may be cut across its longitudinal axis perpendicularly to its longitudinal axis (see, e.g.,  FIG. 6 ). However, in other embodiments, the extruded block may be cut at any other suitable angle that provides a portion including at least a portion of at least one of the one or more holes created at step  802 . The removed portion of the block may be any suitably sized portion of the block, such as a thin slice or a significant portion of the block. In other embodiments, step  804  may be unnecessary and the entire extruded block may be used going forward to step  806 . 
     At step  806 , a housing or other external surface portion of an electronic device may be assembled using the portion or the entirety of the extruded block. In some embodiments, the extruded portion may be provided in a cavity of a housing component of the electronic device. In other embodiments, the extruded portion may be positioned adjacent an outer surface of an electronic component of the electronic device. A portion of at least one hole through the extruded portion of the material may allow information to be communicated between an electronic component of the electronic device and a component external to the electronic device (e.g., sound from a user to a microphone component of the device or light to a user from a light source of the device). 
     In practice, one or more steps shown in illustrative process  800  may be combined with other steps, performed in any suitable order, performed in parallel (e.g., simultaneously or substantially simultaneously), or removed. For example, as mentioned, the entire extruded block of material may be used at step  806 , thereby obviating the need for step  804 . Moreover, additional processing steps may be performed on the extruded block portion before assembling the electronic device. For example, an entire extruded block or an extruded block portion may be forged, bent, drawn, deep drawn, annealed, etched, machined, or subjected to any other suitable processing step. For example, as shown, extruded portion  203  may be forged or bent (e.g., in the direction of arrow B of  FIG. 5A ) to provide a curved extruded portion  203 ′ (see, e.g.,  FIG. 5B ). One or more of the extruded holes  250  of extruded portion  230  may therefore span between curved surfaces of extruded material. 
     While there have been described apparatus and methods for providing holes through housing components and other external surface portions of electronic devices that are aesthetically pleasing, small, and easy to manufacture, it is to be understood that many changes may be made therein without departing from the spirit and scope of the invention. It is also to be understood that various directional and orientational terms such as “front” and “back” and “rear,” “left” and “right,” “top” and “bottom,” “side” and “edge” and “corner,” “height” and “width” and “depth,” “thickness” and “diameter,” and the like are used herein only for convenience, and that no fixed or absolute directional or orientational or geometrical limitations are intended by the use of these words. For example, the devices of this invention can have any desired orientation. If reoriented, different directional or orientational terms may need to be used in their description, but that will not alter their fundamental nature as within the scope and spirit of this invention. Those skilled in the art will appreciate that the invention can be practiced by other than the described embodiments, which are presented for purposes of illustration rather than of limitation, and the invention is limited only by the claims which follow.

Metadata:
Filing Date: 20080923
Publication Date: 20131022
Grant Date: 20131022
Priority Date: 20071130
Inventors: WEBER DOUGLAS JOSEPH
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C2793/0018", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2793/009", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/722", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2709/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3061", "inventive": false, "first": false, "tree": "[]"}, {"code": "F21V33/0052", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2709/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2793/0018", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C48/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3061", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C48/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/722", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2022/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2022/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C48/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2793/009", "inventive": false, "first": false, "tree": "[]"}, {"code": "F21V15/01", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0243", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C48/07", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K5/0243", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C48/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C48/07", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 40675485