PATENT DOCUMENT

Publication Number: US-10547717-B2
Application Number: US-201916241914-A
Country: US
Kind Code: B2

Title: Housing features of an electronic device

Abstract:
An enclosure and a method for forming an enclosure are disclosed. The enclosure may be formed from metal, such as aluminum, and further include a non-metal portion allowing for transmission and receipt of electromagnetic waves. The non-metal portion may be interlocked to the enclosure and in particular, to a region within the enclosure including a first material having a relatively high strength and stiffness compared to the non-metal portion. Interlocking means may include forming dovetail cuts into the enclosure to receive the non-metal portion, a hole or cavity drilled into the enclosure which includes internal threads, and a rod inserted into the first material to provide a tension to the non-metal portion. Methods of assembling internal components using anodization are also disclosed.

Claims:
What is claimed is: 
     
       1. A mobile phone, comprising:
 a display; 
 a transparent cover positioned over the display and defining a front of the mobile phone; and 
 an enclosure coupled to the transparent cover and defining a back, a top side, a bottom side, a first lateral side, and a second lateral side of the mobile phone, the enclosure comprising:
 a first metal enclosure component defining:
 at least a portion of the top side of the mobile phone; 
 a first portion of the first lateral side of the mobile phone; and 
 an interlock feature; 
 
 a second metal enclosure component defining:
 at least a portion of the back of the mobile phone; and 
 a second portion of the first lateral side of the mobile phone; 
 
 a first joining element at least partially occupying a region between the first and the second metal enclosure components; and 
 a second joining element at least partially occupying the region between the first and the second metal enclosure components and engaged with the interlock feature, the second joining element defining a third portion of the first lateral side of the mobile phone. 
 
 
     
     
       2. The mobile phone of  claim 1 , wherein:
 the first metal enclosure component further defines a first portion of the second lateral side of the mobile phone; and 
 the second metal enclosure component defines a second portion of the second lateral side of the mobile phone. 
 
     
     
       3. The mobile phone of  claim 2 , wherein:
 the region between the first and the second metal enclosure components is a first region; 
 the interlock feature is a first interlock feature; 
 the first metal enclosure component further comprises a second interlock feature; and 
 the enclosure further comprises:
 a third joining element at least partially occupying a second region between the first and the second metal enclosure components; and 
 a fourth joining element at least partially occupying the second region between the first and the second metal enclosure components and engaged with the second interlock feature, the fourth joining element defining a third portion of the second lateral side of the mobile phone. 
 
 
     
     
       4. The mobile phone of  claim 2 , wherein the first metal enclosure component is a u-shaped band. 
     
     
       5. The mobile phone of  claim 1 , wherein:
 the first joining element comprises a first polymer material; and 
 the second joining element comprises a second polymer material different from the first polymer material. 
 
     
     
       6. The mobile phone of  claim 1 , wherein the first joining element is mechanically interlocked with the second joining element. 
     
     
       7. The mobile phone of  claim 1 , wherein the interlock feature is a recess in the first metal enclosure component. 
     
     
       8. A mobile phone, comprising:
 an enclosure defining an internal volume and comprising:
 a u-shaped housing component defining:
 at least a portion of a top side of the mobile phone; 
 a first portion of a first lateral exterior side of the mobile phone; and 
 a first portion of a second lateral exterior side of the mobile phone; 
 
 a body component defining:
 a second portion of the first lateral exterior side of the mobile phone; 
 a second portion of the second lateral exterior side of the mobile phone; and 
 at least a portion of a back exterior surface of the mobile phone; 
 
 a first joining element occupying a first portion of a region between the u-shaped housing component and the body component; and 
 a second joining element occupying a second portion of the region between the u-shaped housing component and the body component and retained to the u-shaped housing component via an interlocking structure; 
 a processor positioned in the internal volume; and 
 a display positioned in the enclosure and defining a front exterior surface opposite the back exterior surface. 
 
 
     
     
       9. The mobile phone of  claim 8 , wherein the second joining element defines a third portion of each of the first lateral exterior side and the second lateral exterior side. 
     
     
       10. The mobile phone of  claim 9 , wherein the first, second, and third portions of the first lateral exterior side of the enclosure define a continuous surface. 
     
     
       11. The mobile phone of  claim 8 , wherein the second joining element further defines a portion of the back exterior surface of the mobile phone. 
     
     
       12. The mobile phone of  claim 8 , wherein:
 the u-shaped housing component and the body component comprise a metal material; 
 the first and second joining elements comprise a plastic material; and 
 the mobile phone further comprises an antenna configured to transmit electromagnetic signals through the first and second joining elements. 
 
     
     
       13. The mobile phone of  claim 8 , wherein:
 the u-shaped housing component defines a blind hole; and 
 the second joining element engages the blind hole, thereby interlocking with the u-shaped housing component. 
 
     
     
       14. The mobile phone of  claim 13 , wherein the first joining element is retained to the body component via an additional interlocking structure. 
     
     
       15. An enclosure, comprising:
 a body component defining:
 a portion of a back exterior side of the enclosure; 
 a first portion of each of two lateral sides of the enclosure; and 
 a first interlock feature; 
 
 a first u-shaped housing component defining:
 a top exterior side of the enclosure; 
 a second portion of each of the two lateral sides of the enclosure; and 
 a second interlock feature; 
 
 a second u-shaped housing component defining:
 a bottom exterior side of the enclosure; and 
 a third portion of each of the two lateral sides of the enclosure; 
 
 a first joining element in a region between the first u-shaped housing component and the body component and engaged with the first interlock feature; and 
 a second joining element in the region between the first u-shaped housing component and the body component and engaged with the second interlock feature. 
 
     
     
       16. The enclosure of  claim 15 , wherein:
 the second joining element defines a fourth portion of each of the two lateral sides and a first additional portion of the back exterior side. 
 
     
     
       17. The enclosure of  claim 16 , wherein:
 the enclosure further comprises:
 a third joining element in a region between the second u-shaped housing component and the body component; and 
 a fourth joining element in the region between the second u-shaped housing component and the body component; and 
 
 the fourth joining element defines a fifth portion of each of the two lateral sides and a second additional portion of the back exterior side. 
 
     
     
       18. The enclosure of  claim 15 , wherein:
 the body component, the first u-shaped housing component, and the second u-shaped housing component comprise a metal material; 
 the first joining element comprises a first plastic material; and 
 the second joining element comprises a second plastic material different than the first plastic material. 
 
     
     
       19. The enclosure of  claim 18 , wherein:
 the first interlock feature is a blind hole; and 
 the second interlock feature is a channel. 
 
     
     
       20. The enclosure of  claim 15 , wherein:
 the first joining element defines a third interlock feature; and 
 the second joining element is engaged with the third interlock feature.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application is a continuation patent application of U.S. patent application Ser. No. 15/449,797, filed Mar. 3, 2017 and titled “Housing Features of an Electronic Device,” which is a continuation patent application of U.S. patent application Ser. No. 14/618,744, filed Feb. 10, 2015 and titled “Housing Features of an Electronic Device,” now U.S. Pat. No. 9,591,110, which is a continuation patent application of International Patent Application No. PCT/US15/15127, filed Feb. 10, 2015 and titled “Housing Features of an Electronic Device,” which claims the benefit of U.S. Provisional Patent Application No. 62/047,466, filed Sep. 8, 2014 and titled “Housing Features of an Electronic Device,” and Ser. No. 14/618,744 claims the benefit of U.S. Provisional Patent Application No. 62/047,466, filed Sep. 8, 2014 and titled “Housing Features of an Electronic Device,” the disclosures of which are hereby incorporated herein by reference in their entireties. 
    
    
     FIELD 
     The described embodiments relate generally to an electronic device. In particular, the present embodiments relate to housing features of the electronic device. 
     BACKGROUND 
     It is common for electronic devices to include an antenna or multiple antennas capable of receiving and/or transmitting electromagnetic (“EM”) energy in the form of EM radio waves. Further, these electronic devices typically enclose the antenna(s) within a housing that also encloses several other components. In some cases, the housing is formed from a metal, such as aluminum, which may interfere with transmission and receipt of EM radio waves. In these cases, the housing may include a thin non-metal portion which allows EM radio waves to permeate through the housing. However, this presents several challenges. For example, securing the non-metal portion (such as plastic) to a metal housing may disengage, or deflect from, the metal housing if a load or force is exerted on the electronic device, such as during a drop event. Also, laminating the non-metal material is difficult in instances where the non-metal portion is relatively thin, as adhesive or other securing means tends to appear on the exterior surface of the housing, which is undesired. 
     The non-metal portion may also extend around a sidewall of the enclosure. In these locations (on the sidewall), the enclosure includes a space or void filled only with material used to form the non-metal portion. These locations also form part of a base that receives a display panel and cover glass. As a result, the display panel and the cover glass may subject the non-metal portion to breaking or cracking during a drop event. 
     SUMMARY 
     In one aspect, an enclosure is described. The enclosure may include a first region formed in an interior portion of the enclosure. The first region may include a first material filled or molded into the first region. The enclosure may further include a second region formed in an exterior portion of the enclosure. The second region may include a second material filled or molded into the exterior portion. The second material may be different than the first material. The enclosure may further include a protrusion integrally formed with the enclosure. The protrusion may extend through the first material. The enclosure may further include a means for interlocking the second material to the first material. In some cases, the first material engages the second material to define an interface region. 
     In another aspect, a method for assembling an electronic device is described. The method may include removing a first region of material in an interior portion of an enclosure. The method may further include filling the first region with a first material. The method may further include removing a second region of material in an exterior portion of the enclosure. The exterior portion defines an outer portion or region of the enclosure, and is opposite the interior portion that defines an inner portion that receives one or more internal components. The method may further include filling the second region with a second material different from the first material. The method may further include interlocking the second material to the first material. 
     In another aspect, an enclosure of an electronic device is described. The enclosure includes an interior portion that receives an internal component and an exterior portion that defines an outer region of the enclosure. The enclosure may include a first sidewall. The enclosure may include a second sidewall opposite the first sidewall. The enclosure may include a first region formed in the internal portion. In some cases, the first region extends from the first sidewall to the second sidewall; the first region may include a first material within the first region. The enclosure may further include a second region formed in the exterior portion. In some cases, the second region extends from the first sidewall to the second sidewall. The second region may include a second material within the second region. The enclosure may further include a cavity that receives at least some of the second material. In some embodiments, the first material is engaged with the second material. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  illustrates an electronic device, in accordance with the described embodiments; 
         FIG. 2  illustrates a plan view of a rear portion of the electronic device shown in  FIG. 1 , showing an exterior portion of the enclosure; 
         FIG. 3  illustrates a plan view of a front portion the electronic device shown in  FIG. 1 , showing an interior portion of the enclosure; 
         FIG. 4  illustrates a cross sectional view of the enclosure shown in  FIG. 3  taken along the  4 - 4  line, showing the enclosure having material removed from the enclosure to define a first inner region in which a first inner material may be received; 
         FIG. 5  illustrates a cross sectional view of the enclosure shown in  FIG. 4 , further showing the first inner material filled within the first inner region; 
         FIG. 6  illustrates a cross sectional view of the enclosure shown in  FIG. 5 , further showing the enclosure having undergone an additional material removal process to define a first outer region; 
         FIG. 7  illustrates a cross sectional view of the enclosure shown in  FIG. 6 , further showing a first outer material positioned within the first outer region; 
         FIG. 8  illustrates a cross sectional view of the enclosure showing the enclosure having a cavity drilled into the enclosure, the cavity including a threaded region, in accordance with the described embodiments; 
         FIG. 9  illustrates a cross sectional view of the enclosure showing the cavity shown in  FIG. 8 , with the first outer material filling the cavity and the threaded region; 
         FIG. 10  illustrates a cross sectional view of the enclosure shown in  FIG. 9 , having a first inner material with a rod member positioned within the first inner material, in accordance with the described embodiments; 
         FIG. 11  illustrates a cross sectional view of the enclosure shown in  FIG. 9 , showing a rod member used in various configurations, in accordance with the described embodiments; 
         FIG. 12  illustrates a plan view of an electronic device showing an interior portion of an enclosure, further showing several marks and symbols used as guides for assembling internal components within the enclosure, in accordance with the described embodiments; 
         FIG. 13  illustrates a cross sectional view of an exemplary first mark shown in  FIG. 12 , taken along the  13 - 13  line; 
         FIG. 14  illustrates a cross sectional view of an exemplary first mark shown in  FIG. 13 , further having a laser etched mark within the enclosure; 
         FIG. 15  illustrates a cross sectional view of an exemplary first mark shown in  FIG. 13 , further undergoing a crazing process in which laser etched marks are made within an anodized region; 
         FIG. 16  illustrates a plan view of an enlarged area of an interior portion of an electronic device, in accordance with the described embodiments; 
         FIG. 17  illustrates an isometric side view of a region enclosed by Section A shown in  FIG. 16 , showing a first outer material and an upper sidewall including a first ridge feature and a second ridge feature, respectively; 
         FIG. 18  illustrates an embodiment of the first ridge feature shown in  FIG. 17  formed from additional material such that an area beneath the first ridge feature includes a greater thickness than that of the previous embodiment (shown in  FIG. 17 ); 
         FIG. 19  illustrates a plan view of an enlarged area of an interior portion of an electronic device having an extension within an opening, in accordance with the described embodiments; 
         FIG. 20  illustrates an isometric view of a region enclosed by Section B shown in  FIG. 19 , showing the first outer material and an upper sidewall having an extension that extends into the first outer material; 
         FIG. 21  illustrates an isometric view of a region similar to that of the region enclosed by Section B shown in  FIG. 19 , showing a gusset member insert molded into the first outer material; 
         FIG. 22  illustrates an isometric view of a region similar to that of the region enclosed by Section B shown in  FIG. 19 , showing several rod members insert molded within the first outer material; 
         FIG. 23  illustrates a flowchart showing a method for assembling an electronic device; 
         FIG. 24  illustrates an isometric view of a portion of a first outer material having an extension, in accordance with the described embodiments; 
         FIG. 25  illustrates an isometric view of an enlarged portion of an enclosure with a first inner material molded into the enclosure, with the first inner material and the enclosure having material removed to receive the first outer material; 
         FIG. 26  illustrates an embodiment of an electronic device having an enclosure using several protrusions as fasteners, in accordance with the described embodiments: 
         FIG. 27  illustrates an isometric view of the enclosure having a first protrusion secured within a first fastening member; and 
         FIG. 28  illustrates a cross sectional view showing an internal component secured to the enclosure via a first fastener. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The following disclosure relates to an enclosure of an electronic device. In particular, the enclosure may be formed from a metal substrate, such as aluminum, and also from a non-metal material (or materials) through which electromagnetic (“EM”) radio waves may pass. An interior portion, or interior surface, of the enclosure may include a first material molded into a first region formed by a material removal process that includes the use of a removal tool, such as a computer numerical control (“CNC”) tool. An exterior portion, or exterior surface defined by an outer region of the enclosure, may include a second material molded into a second region. The second material may provide a cosmetic or aesthetic appearance to the enclosure. The first material may be formed from rigid materials such that the first material is relatively rigid or stiff with respect to the second material. The second material may engage or interlock with first material, thereby defining a region of the enclosure free of the metal substrate. In this manner, when the first material and the second material are made substantially from non-metallic materials, one or more radios (e.g. Wi-Fi radio, Bluetooth radio, cellular radio, NFC radio) within the electronic device may transmit and receive EM radio waves via antennas. As a result, the enclosure may be substantially formed from a robust metal yet include a cosmetic second material supported by a rigid or stiff first material, with the first and second materials allowing for permeation of EM radio waves. 
     The second material may be interlocked to the enclosure and/or the first material. In some embodiments, the enclosure includes a cavity, or several cavities, around a sidewall of the enclosure. The cavity may include internal threads. When the enclosure is filled with the second material, the second material, prior to curing, flows into the cavity and is further secured to the enclosure by the internal threads. Also, a rod member (or rod members) may be positioned within the first material prior curing the first material. When the first material cures, the rod member may provide not only additional stiffness but also a tension to the second material that may resist a load exerted on the second material, thereby providing improved securing means of the second material to the enclosure. 
     Also, in some embodiments, the enclosure includes several lines or symbols to assist with assembling various components within the electronic device. For example, the lines or symbols may provide a guide to an operator indicating where an internal component should be assembled. The lines and symbols may be formed by an anodization process. Further, in some embodiments, a portion of the line or symbol formed by the anodization process may be removed by laser-etching. Also, in cases where automated assembly of the electronic device is performed, the lines or symbols may indicate to a visual system (e.g., CCD camera) a location at which another internal component should be assembled. In this manner, the visual system may provide an input to a control system which signals to, for example, a robotic assembly to place an internal component at a desired location as determined by the visual system. This may provide for a highly repeatable process desired during assembly. 
     Also, in some embodiments, the second material extends around sidewalls of the enclosure to define split regions in which the sidewalls are free of the metal material forming the enclosure. In these embodiments, the second material may be strengthened. For example, in some embodiments, a material removal process may be formed in the sidewalls to define an extension (e.g., dovetail) that extends into and beyond the split region. In this manner, the second material may be filled or molded around the extension. Further, in some embodiments, a gusset may be molded (e.g., insert molded) into the second material. Also, in some embodiments, several rods or cylinders may be molded into the second material in a location associated with the split region. 
     These and other embodiments are discussed below with reference to  FIGS. 1-28 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1  illustrates an embodiment of electronic device  100 , or simply device  100 . In some embodiments, device  100  is a mobile telecommunications device, such as an iPhone® from Apple, Inc., of Cupertino, Calif. In some embodiments, device  100  is a tablet computing device, such as an iPad, from Apple, Inc., of Cupertino, Calif. Device  100  may include enclosure  102  that receives cover glass  104 . In some embodiments, enclosure  102  is formed from a metal material, such as aluminum or aluminum alloy. Also, display panel  106  may be positioned between cover glass  104  and enclosure  102 . Display panel  106  may be configured to transmit visual display content to a user. Also, in some embodiments, enclosure  102  includes a sidewall  108  having openings, such as first opening  110  and second opening  112 . First opening  110  and second opening  112  may be filled by a non-metal material, such as plastic or resin. First opening  110  and second opening  112  may be referred as a split region, as these area define an area in which the sidewalls (e.g., sidewall  108 ) are discontinuous. 
       FIG. 2  illustrates a rear portion of device  100  shown in  FIG. 1 , showing an exterior portion of enclosure  102 . While enclosure  102  is formed substantially from a unitary material (e.g. metal), enclosure  102  may include several regions generally free of the unitary material. For example, enclosure  102  may include first outer region  114  and second outer region  116 . In some embodiments, first outer region  114  and second outer region  116  are formed from a material removal process by cutting or removing material from enclosure  102 . Further, first outer region  114  and second outer region  116  may include first outer material  124  and second outer material  126  positioned within first outer region  114  and second outer region  116 , respectively. In some embodiments, first outer material  124  and second outer material  126  are molded within first outer region  114  and second outer region  116 , respectively, after the material removal process. 
     Also, in some embodiments, first outer material  124  and second outer material  126  are formed from a non-metal material, such as plastic. In this manner, device  100  may include a radio, not shown, positioned behind first outer region  114  and/or second outer region  116  (i.e., within device  100 ). The radio may include an antenna that transmits or receives EM waves, such as radio waves, through a substantially metal enclosure  102  via first outer material  124  and second outer material  126 . Generally, first outer material  124  and second outer material  126  may be formed from the same or substantially similar composition of materials, with the composition of materials allowing EM waves used for telecommunications, data transfer, or the like. Also,  FIG. 2  shows first outer material  124  and second outer material  126  extending around the sidewalls of enclosure  102 . For example, first outer material  124  extends around sidewall  108  and into first opening  110 , while second outer material  126  extends around sidewall  108  and into second opening  112 . Also, first outer material  124  and second outer material  126  may include a variety of colors, such as red, blue, green, black, white, or a combination thereof. Generally, the color or colors selected provides a desired aesthetic appearance. 
       FIG. 3  illustrates a plan view of device  100  showing an interior portion of enclosure  102 . For purposes of illustration, several internal components (e.g., processor circuits, memory circuits, flexible circuits, battery, etc.) are removed. Similar to the exterior portion, the interior portion may include several regions free of the unitary material used to form enclosure  102 , such as first inner region  144  and second inner region  146 . First inner region  144  and second inner region  146  may be formed by a material removal process previously described for first outer region  114  and second outer region  116  (shown in  FIG. 2 ). However, the respective regions may include different shapes. In some embodiments, first inner region  144  and second inner region  146  are cut by a substantially similar code input into a cutting tool. In the embodiment shown in  FIG. 3 , first inner region  144  is different from second inner region  146 . For example, second inner region  146  includes first protrusion  148  and second protrusion  150 , both of which may be integrally formed with enclosure  102 . In other words, first protrusion  148  and second protrusion  150  may be formed from (i.e., cut into) the same substrate used to make enclosure  102 . In other embodiments, first inner region  144  also includes protrusions. 
     First inner region  144  and second inner region  146  may include first inner material  154  and second inner material  156  positioned within first inner region  144  and second inner region  146 , respectively. As shown, first inner region  144  is proximate to sidewall  134  and second inner region  146  is proximate to sidewall  136 . In some embodiments, first inner material  154  and second inner material  156  are formed by a molding process within first inner region  144  and second inner region  146 , respectively. Also, in some embodiments, first inner material  154  and second inner material  156  are formed form a different composition of materials than that of first outer material  124  and second outer material  126  (shown in  FIG. 2 ). In the embodiments shown in  FIG. 3 , first inner material  154  and second inner material  156  are formed from the same or substantially similar composition of materials, and may include a plastic or resin material combined with particles including glass, metal (e.g., aluminum), or a combination thereof. As a result, first inner material  154  and second inner material  156 , when cured, form a relatively rigid and stiff structure configured to provide support to first outer material  124  and second outer material  126 , respectively. Also, the composition of materials used to form first inner material  154  and second inner material  156  allows transmission of EM radio waves. Accordingly, first outer material  124  and first inner material  154  may combine to allow EM waves to be transmitted or received by a radio antenna located within enclosure  102 . A similar EM transmission/reception may occur via second outer material  126  and second inner material  156 . 
       FIGS. 4-11  illustrate a cross sectional view of the embodiment shown in  FIG. 3  taken along the  4 - 4  line, showing various features and embodiments that may be used to form enclosure  102 . In some cases,  FIGS. 4-11  illustrate various steps in forming enclosure  102 . However, while these features are shown directed to a particular location along first inner region  144  of enclosure  102  (the cross sectional region of  FIG. 3 ), these features and embodiments may be located in any region along sidewall  134  and/or sidewall  136  (shown in  FIG. 3 ). 
       FIG. 4  illustrates a cross sectional view showing enclosure  102  having material removed from enclosure  102  to define first inner region  144  in which a first inner material may be received. In some embodiments, first inner region  144  includes first indention  162  and second indention  164 . In some embodiments, first indention  162  and second indention  164  form a dovetail configuration that secures the inner material filled or molded within first inner region  144 . Also, although not shown, second indention  164  may be positioned beneath a protrusion configured to further secure filled or molded material to first inner region  144 . 
       FIG. 5  illustrates a cross sectional view of enclosure  102  shown in  FIG. 4 , further showing first inner material  154  positioned within first inner region  144 . First inner material  154  may be applied by molding, including injection molding, printing, or any technique known in the art for applying a resin or plastic material to a metallic enclosure. 
       FIG. 6  illustrates a cross sectional view of enclosure  102  shown in  FIG. 5 , further showing enclosure  102  having undergone an additional material removal process to define first outer region  114  (previously shown in  FIG. 2 ). In some embodiments, first inner region  144  and first outer region  114  are formed prior to adding first inner material  154 . In the embodiment shown in  FIG. 6 , first inner region  144  receives first inner material  154  prior to forming first outer region  114 . In this manner, a portion of first inner material  154  may be removed during the process used to form first outer region  114 . Also, first outer region  114  may include thickness  161  in a direction (e.g., y-direction) approximately in the range of 1.5 to 3 mm. Also, first outer region  114  may be in a location associated with any of the four sidewalls of enclosure  102  (such as sidewall  134  or sidewall  136 ). 
       FIG. 7  illustrates a cross sectional view of enclosure  102  shown in  FIG. 6 , further showing first outer material  124  positioned within first outer region  114 . Along with the various color combinations, first outer material  124  may further include a desired aesthetic or cosmetic look and feel by being formed within first outer region  114  in a manner such that first outer material  124  is substantially co-planar, or flush, with respect to an exterior portion of enclosure  102 . Also, first outer material  124  may be applied to enclosure  102  in any manner described for first inner material  154 . Also, as shown in  FIG. 7 , first outer material  124  is engaged with first inner material  154  defining an interface region  160 . The interface region  160  may be referred to as a region of enclosure  102  substantially free of the metal substrate used to form enclosure  102 . Due in part to the substantial non-metal compositions of first outer material  124  and first inner material  154 , transmission of EM waves may pass to and from the electronic device at the interface region  160  despite enclosure  102  being formed of a substantially unitary metal substrate. This includes instances in which first inner material  154  includes some metallic particles. 
     In instances when first outer material  124  is not adhesively secured to enclosure  102  and/or first inner material  154 , additional features may be used to prevent first outer material  124  from disengaging or deflecting outward (with respect to enclosure  102 ) during a load or force acting on enclosure  102 . For example,  FIGS. 8 and 9  illustrate a cross sectional view of enclosure  102  having cavity  170  formed within enclosure  102 , and in particular, within first outer region  114 . Cavity  170  may also be positioned within at least a portion of a sidewall of enclosure  102 . Cavity  170  may be formed by a material removal tool, such as a drill or pilot drill. In some embodiments, cavity  170  includes internal threads  172 .  FIG. 9  illustrates first outer material  124  positioned or molded within first outer region  114 , and also in a manner such that first outer material  124  fills cavity  170  and internal threads  172  prior to first outer material  124  curing. In the enlarged view in  FIG. 9 , once first outer material  124  cures, first outer material  124  includes a virtual threaded screw integrally formed with first outer material  124 . This feature may secure first outer material  124  from outward deflection caused by a load or force received by enclosure  102  in the x-, y-, and/or z-directions. Also, although not shown, a cavity having internal threads may be formed within enclosure  102 , thereby providing additional securing means for first inner material  154  to enclosure  102  in a manner similar to that of first outer material  124 . Further, in some embodiments, two or more cavities (similar to cavity  170 ) having internal threads may be formed within enclosure  102 , such that screw-like features are integrally formed with first outer material  124  and/or first inner material  154 . 
     In some embodiments, first inner material  154  may be configured to provide additional securing features. For example,  FIG. 10  illustrates a cross sectional view of enclosure  102  having first inner material  154  with a rod member  180  positioned within first inner material  154 . In some embodiments, rod member  180  is formed from a ceramic material. Generally, rod member  180  may be made from any material or materials that do not interfere with transmission of EM waves. Also, in some embodiments, rod member  180  is insert molded into first inner material  154 . In other words, rod member  180  is positioned within first inner material  154  during a molding process of first inner material  154  and prior to curing thereof. In other embodiments, rod member  180  includes a threaded region at a single end or at both ends. Rod member  180  may be configured to provide a “pre-tension” on first outer material  124 , particularly in areas proximate to first opening  110  and/or second opening  112  (shown in  FIG. 1 ). The term “pre-tension” refers to a tension or stress that may be in a direction opposite a direction of a load or force exerted on enclosure  102  and/or first outer material  124 . In this manner, rod member  180  may offset a deflection force acting on first outer material  124  which increases the probability of first outer material  124  remaining intact. Rod member  180  may also act as a rebar providing additional strength to first inner material  154 . Also, in some embodiments, rod member  180  may be heated in order to expand from a first volume to a second volume greater than the first volume. While heated, rod member  180  is insert molded into first inner material  154 . When rod member  180  cools, it may shrink to the first volume. However, while doing so, it may also shrink first inner material  154  to provide additional tension. 
       FIG. 11  illustrates a cross sectional view of enclosure  102  showing multiple rod members used in various configurations. For example, in some embodiments, enclosure  102  may include several cavities or openings allowing first rod member  182  and second rod member  184  to be fastened or secured to the cavities or openings of enclosure  102 , which may provide additional securing means for first inner material  154  to enclosure  102 . Also, in some embodiments, third rod member  186  may be insert molded in both first inner material  154  and first outer material  124  thereby providing a physical interlock between first inner material  154  and first outer material  124 . Also, in some embodiments (not shown), the cavities used to receive the rod members may be threaded. In these embodiments, rod members (not shown) may also be threaded and configured for threaded engagement with the cavities. Further, first rod member  182 , second rod member  184 , and/or third rod member  186  can be used in any configuration that does not close an electrical connection between otherwise non-electrically connected components. 
       FIG. 12  illustrates a plan view of electronic device  200  showing an interior portion of enclosure  202 , further showing several marks and symbols used as guides for assembling internal components within enclosure  202 , in accordance with the described embodiments. For example, enclosure  202  may include first mark  210  and second mark  212  used in concert as guides for first internal component  216 , which may be an internal component, such as a processor or a flexible circuit. In some embodiments, first mark  210  and second mark  212  are located in an area of enclosure  202  on opposite sides of first internal component  216  in order to act as a guide for positioning first internal component  216 . Also, enclosure  202  may further include third mark  220  and fourth mark  222  used in concert as guides for second internal component  226 , which may include an internal power supply. Third mark  220  and fourth mark  222  may be selected from various visual symbols, such as a circle, triangle, or a four-sided figure (e.g., rectangle). In the embodiment shown in  FIG. 12 , third mark  220  and fourth mark  222  are both in the shape of a plus (“+”) sign. In other embodiments, third mark  220  includes a shape different from that of fourth mark  222 . 
     In addition to acting as guides for an assembly operator, first mark  210 , second mark  212 , third mark  220 , and/or fourth mark  222  may be used as fiducial markers used by a vision or imaging system (not shown) that is part of an automated assembly machine (not shown). In this manner, the vision system may detect any of first mark  210 , second mark  212 , third mark  220 , and/or fourth mark  222 , and provide an input to the assembly machine, the input referring to a location on enclosure  202 . The assembly machine may then output a signal to a robotic arm carrying, for example, second internal component  226 . The assembly machine may be configured to position second internal component  226  in a location between third mark  220  and fourth mark  222 . These marks shown in  FIG. 12  offer greater repeatability in assembly over using other internal features or previously assembled components within device  200 , particularly when using an automated assembly process having a vision system. 
     Also, in some embodiments, first mark  210 , second mark  212 , third mark  220 , and fourth mark  222  are formed by an anodizing process. Further, to allow the vision system to first distinguish the aforementioned marks from “false positives” which may include machining marks form by a CNC tool, first mark  210 , second mark  212 , third mark  220 , and fourth mark  222  may include a laser etching to remove a portion of the marks. 
       FIG. 13  illustrates a cross sectional view of an exemplary first mark  210  shown in  FIG. 12 , taken along the  13 - 13  line. First mark  210  can be formed by laser etching portions of an anodic film formed on enclosure  202  that is anodized, in order to define first mark  210 . In some embodiments, a laser beam is rastered over the anodic film in order to form first mark  210 . In this manner, the laser etched portions define regions where the anodic film is removed. The laser etching process may recess first mark  210  relative to remaining surfaces of enclosure  202 . This recessed portion may include a height  218  approximately in the range of 8-15 micrometers. The region  230  (dotted lines) refers to a space previously occupied by first mark  210  and removed by the laser removal process. This may be used to further assist a vision system in distinguishing first mark  210  from another feature of enclosure  202 , including second mark  212 . 
       FIGS. 14 and 15  illustrate alternative embodiments of first mark  210  having different laser etched features. In  FIG. 14 , after a portion of first mark  210  is removed, a laser etch tool may form a laser etch mark  232  between a region defining first mark  210  and below a surface of enclosure  202  which may be recognized in a unique and distinct manner by a vision system previously described. 
       FIG. 15  illustrates a crazing process in which laser etched marks are made within first mark  210 . In other words, a laser etching process may be performed on an anodized region. For example, first mark  210  includes first laser etch mark  234  in a central region of first mark  210 . Also, first mark  210  includes second laser etch mark  236  and third laser etch mark  238 , both of which are proximate to an interface region between first mark  210  and enclosure  202 . This crazing process may be performed in a manner such that a vision system may distinguish first laser etch mark  234  from second laser etch mark  236  and third laser etch mark  238 . It will be appreciated that any combination of laser etch marks shown in  FIGS. 13-15  may be used on any of first mark  210 , second mark  212 , third mark  220 , and fourth mark  222  shown in  FIG. 12 . Further, in the embodiments shown in  FIGS. 13-15 , the portion removed by a laser ablation process (e.g., region  230 ) may also serve as an electrical grounding path for some internal components electrically connected to the electrical grounding path. The electrical grounding path may be part of enclosure  202  (shown in  FIG. 12 ) as the anodized regions surrounding the grounding path are (relatively) inert electrically. Also, the grounding path may be electrically connected to a grounding foam. In this manner, the grounding foam may be electrically connected to the internal component(s). 
     The anodization process previously described may be performed subsequent to molding, for example, first inner material  254  and first outer material  224  (shown in  FIG. 12 ) to enclosure  202 . Accordingly, first inner material  254  and first outer material  224  are exposed to the anodization process. This may be performed in order to improve the cosmetic appearance of enclosure  202  and/or improve the resistance of enclosure  202  to damage, such as scratching. In some cases, the anodization process is performed near the final assembly process of an electronic device. Generally, materials formed from plastic, such as first outer material  224  and first inner material  254 , may be eroded when enclosure  202  undergoes an anodization “bath” that may include chemicals such as phosphoric acid, sulfuric acid, and/or oxalic acid, all of which may be heated to a temperature well above room temperature. 
     However, in the described embodiments, first outer material  224  and first inner material  254  include a unique plastic material or materials allowing first outer material  224  and/or first inner material  254  to resist erosion during the anodization process. Since anodizing generally involves immersing a part in an acidic electrolytic bath that can be heated, first outer material  224  and/or first inner material  254  should be resistant to chemical breakdown or other deformation when exposed to an acidic electrolytic bath. Further, first outer material  224  and first inner material  254  are designed to retain their original color and stiffness. This may be due in part to several features of first outer material  224  and first inner material  254 . For example, first outer material  224  and first inner material  254  may each include a plastic material or materials free of hydroscopic materials that absorb water. In this manner, any water associated with the anodization bath will not be absorbed by first outer material  224  and first inner material  254 . Further, the dimensions and tolerances of enclosure  202  (e.g., regions which receive first outer material  224  and first inner material  254 ) do not affect or disturb first outer material  224  and first inner material  254 . Also, first inner material  254  may further include a material makeup such that a ridge feature (discussed below) does not become brittle or weak. In this manner, first inner material  254  remains strong enough to hold a display cover. 
     In some embodiments, first outer material  224  and/or first inner material  254  may be made from materials that include miscible blends of the Polyarylether Keytone (PAEK) family (PEEK, PEK, PEKK) and Polysulfone family (PSU, PPS, PES, PPSU, and PPS). These material compositions may include glass fibers to increase strength or adjust rheological properties to improve blend homogeneity. Further, the composition of materials forming first outer material  224  and/or first inner material  254  may be chemically resistant and retain their geometries when exposed to one or more additional processes subsequent to anodization. Such post-anodizing processes can include exposure to ultraviolet light (e.g., by exposure to an ultraviolet curing process), chemical coating, CNC cutting, blasting (e.g., sandblasting), and polishing. Other factors in determining the material(s) used to form first outer material  224  and/or first inner material  254  include strength sufficient to withstand impact during a drop event of enclosure  202 , moldability of the material(s) (such that first outer material  224  and/or first inner material  254  can be properly molded within gaps and offsets of enclosure  202 ), and ability to form an external skin that is resistant to exposing internal portions of the polymer material. 
       FIG. 16  illustrates a plan view of an enlarged area of an interior portion of device  300 , in accordance with the described embodiments. Similar to previous embodiments, device  300  may include enclosure  302  having second sidewall  334  positioned between first sidewall  308  and third sidewall  318 . Also, enclosure  302  may further include opening  310  that may be referred to as a split region within first sidewall  308 . Opening  310  may be filled within first outer material  324  that may be an insert molded material formed on an exterior portion of enclosure  302  in a manner previously described. 
       FIG. 17  illustrates an isometric side view of a region enclosed by Section A shown in  FIG. 16 , showing first outer material  324  and first sidewall  308 . As shown, first outer material  324  includes first ridge feature  326  and first sidewall  308  includes second ridge feature  336 . First ridge feature  326  and second ridge feature  336  are designed to be substantially continuous such that a component (e.g., display panel  106 , in  FIG. 1 ) may lie flat, or level, on both first ridge feature  326  and second ridge feature  336 . Due to their respective material compositions, first ridge feature  326  may include different properties than that of second ridge feature  336 . For example, second ridge feature  336  may be relatively stiff or rigid as compared to first ridge feature  326 , as second ridge feature  336  is formed from metal, such as aluminum, and first ridge feature  326  is formed from a material such as plastic. As a result, first ridge feature  326  may be prone to cracking, including micro-cracking, and/or breaking if enclosure  302  is exposed to certain load-bearing events. 
     In order to provide additional support to first ridge feature  326  without changing its material makeup, several techniques may be used. For example,  FIG. 18  illustrates an embodiment of first ridge feature  326  shown in  FIG. 17  formed with additional material such that an area beneath first ridge feature  326  includes a greater thickness than that of the previous embodiment (shown in  FIG. 17 ). The dotted line illustrates a region or volume below which additional material is added to first outer material  324  (as compared to the embodiment in FIG.  17 ). In this manner, first ridge feature  326  may be designed to withstand a load having a force in the direction denoted by the arrow, A 1 . 
       FIGS. 19 and 20  illustrate an embodiment of device  400  showing a different technique for providing additional structural support to first outer material  424 , in accordance with the described embodiments. For example, sidewall  408  may include a material removal process within opening  410  such that first extension  412  and second extension  414  are formed within opening  410 . In other words, first extension  412  and second extension  414  are integrally formed with sidewall  408 , and accordingly, are formed from the same material as the enclosure and sidewall  408 . In some embodiments, first extension  412  and second extension  414  include a dovetail configuration around which first outer material  424  may be filled or molded. 
       FIG. 20  illustrates an isometric view of a region enclosed by Section B shown in  FIG. 19 , showing first outer material  424  and sidewall  408 . Sidewall  408  may include first extension  412  that extends into first outer material  424 . Due to the machining process used to form first extension  412 , first extension  412  is integrally formed with sidewall  408 . As a result, first extension  412  is also formed from a metal material (e.g., aluminum). Accordingly, first extension  412  may provide additional structural support to first outer material  424 . 
       FIGS. 21 and 22  illustrate alternate embodiments showing techniques designed to provide structural support to an opening (such as opening  410 , shown in  FIG. 19 ), in accordance with the described embodiments.  FIG. 21  illustrates an isometric view of a region similar to that of the region enclosed by Section B shown in  FIG. 19 , showing gusset member  530  insert molded into first outer material  524 . Gusset member  530  may be secured to sidewall  508  and be made from rigid materials such as metal or hard plastic.  FIG. 22  illustrates an isometric view of a region similar to that of the region enclosed by Section B shown in  FIG. 19 , showing several rod members  640  insert molded within first outer material  624 . Rod members  640 , which include first rod member  642  and second rod member  644 , may be secured to sidewall  608 . In some embodiments, several cavities are formed within sidewall  608  configured to receive rod members  640 . Also, rod members  640  may be made from any material, or materials, generally known to be non-electrically conductive. It will be appreciated that the techniques described in  FIGS. 19-22  may be used in any one of the four split regions generally associated with an enclosure. 
       FIG. 23  illustrates a flowchart  700  showing a method for assembling an electronic device. In step  702 , a first region of material is removed from an interior portion of an enclosure. The first region may be a channel extending along the enclosure proximate to a location associated with the positioning of a radio antenna of the electronic device. 
     In step  704 , the first region is filled with a first material. In some embodiments, the first material includes a composition of materials selected from a plastic combined with particles that includes glass, metal (e.g., aluminum), or a combination thereof. Also, the first material may be configured to allow the radio antenna to transmit or receive EM waves. 
     In step  706 , a second region of material is removed from an exterior portion of the enclosure. The exterior portion is associated with an outer surface generally visible, and may be referred to as a portion opposite the interior portion. The second region may be a channel extending around the enclosure proximate to a location associated with the positioning of the radio antenna of the electronic device. 
     In step  708 , the second region is filled with a second material different from the first material. The second material may be a relatively thin material configured to provide a cosmetic finish, and may be one of a variety of colors. Also, the second material is formed substantially from plastic, and is less rigid and less stiff as compared to the first material. Also, the second material may be engaged with the first material at an interface region. In this manner, the first material and the second material may combine to allow the radio antenna to transmit or receive EM waves, while also allowing for the enclosure to be formed substantially from a metal material, such as aluminum. 
     In step  710 , a means for interlocking the second material to the first material is provided. In some embodiments, the means include a cavity including a threaded region in the cavity. The second material may occupy the second region as well as the cavity and the threaded region. In some embodiments, the means include a rod member that provides a tension, or pre-tension, to the first material. The tension may offset a load incurred by the enclosure and/or second material. Further, in some embodiments, several rod members may be used. The rod members may interlock the first material to the enclosure and/or the second material, thereby providing for additional structural support. 
       FIGS. 24 and 25  illustrate an alternative of an electronic device, and in particular, by first inner material  854 , in accordance with the described embodiments.  FIG. 24  illustrates an isometric view of a portion of first outer material  824 . In some embodiments, extension  826  is includes a dovetail configuration. Also, in some embodiments, extension  826  is formed by insert molding a rigid material (e.g., plastic) that produces a desired shape (e.g., dovetail). In other embodiments, extension  826  is formed during an alternate molding process of first outer material  824  into the enclosure. Also, extension  826  may extend in another direction to form a symmetrical shape around first outer material  824  (i.e., two dovetails). 
       FIG. 25  illustrates an isometric view of an enlarged portion of enclosure  802  with first inner material  854  molded into enclosure  802 . Subsequent to molding first inner material  854  into enclosure  802 , enclosure  802  and/or first inner material  854  may include a material removal process (e.g., CNC cutting) in order to receive a portion of first outer material  824  (shown in  FIG. 24 ). For example, region  856  may be removed by removing material from enclosure  802  (in particular, sidewall  808  of enclosure  802 ) and first inner material  854 . In this manner, extension  826  (shown in  FIG. 24 ) may be molded or formed within region  856 . As a result, first outer material  824  may be further secured to enclosure  802 . This allows for first outer material  824  to better withstand load-bearing events and reduce instances of first outer material  824  deflecting away from enclosure  802 . Generally, region  856  may be formed with any desired shape to form a corresponding shape of extension  826 . 
     In addition to using anodized fiducials, other methods and techniques may be used to align internal components as well as reduce the overall footprint of alignment features. For example,  FIG. 26  illustrates an embodiment of electronic device  900  having enclosure  902  using several protrusions as fasteners, in accordance with the described embodiments. Traditional devices include protrusions (used for aligning an internal component during assembly) positioned proximate to openings (used for receiving a fastener to secure the internal component). This uses additional, unnecessary space within enclosure  902 . However, in this embodiment, the protrusions are positioned within the openings while still providing alignment to, for example, an automated assembly process that uses a vision system to determine the location of the protrusion. Further, the protrusions also include openings used to receive a fastener. In other words, the protrusions serve a dual purpose: alignment and fastening. In some embodiments, the openings include an internal threaded region configured to receive a fastener (e.g., screw) used to secure the internal component (e.g., main logic board).  FIG. 26  shows enclosure  902  having an exemplary first protrusion  910  having first cavity  912  with an internal threaded region. 
       FIG. 27  illustrates an isometric view of enclosure  902  having first protrusion  910  secured within fastening member  914 . In some embodiments, fastening member  914  is a nut having a sleeve. Also, first protrusion  910  includes first cavity  912  having internal threaded region  916  configured to receive a fastener (not shown). In other embodiments, first cavity  912  does not include an internal threaded region in order to secure an unthreaded fastener (e.g., rivet). In this configuration, fastening member  914  and first protrusion  910  provide for alignment means of an internal component, and also a securing means for the internal component. This allows the internal component to include additional area for additional features. 
       FIG. 28  illustrates a cross sectional view showing a portion of internal component  922  secured to enclosure  902  via fastener  924 . In some embodiments, fastener  924  is a boss. Fastener  924  may include a threaded region configured for threaded engagement with an internal threaded region of first cavity  912 . First protrusion  910  and fastener  924  include certain relationships to ensure internal component  922  is properly secured. For example, a dimension  932 , or gap, between a lower portion of fastener  924  and an upper portion of first protrusion  910  ensures that when fastener  924  is secured to first protrusion  910 , internal component  922  is engaged with both enclosure  902  and fastener  924 . Also, as shown in  FIG. 28 , fastener  924  includes a dimension  942  (e.g., height in a z-direction) extending above enclosure  902 . This dimension  942  includes a height or thickness less than a height or thickness of dimension  944  of internal component  922 . In this manner, fastener  924  may be secured to first protrusion  910  in a manner such that fastener  924  contacts internal component  922  to better secure internal component  922  to enclosure  902 . 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20190107
Publication Date: 20200128
Grant Date: 20200128
Priority Date: 20140908
Inventors: HILL, MATTHEW D.
KRASS, DEREK C.
BUSTLE, BENJAMIN SHANE
BROWNING, LUCY ELIZABETH
WITTENBERG, MICHAEL BENJAMIN
SMITH, JAMES B.
SHUKLA, ASHUTOSH Y.
MYERS, SCOTT A.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/23", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/0247", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0202", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0202", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0249", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/0247", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/23", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 55438660