PATENT DOCUMENT

Publication Number: US-10279564-B2
Application Number: US-201414216614-A
Country: US
Kind Code: B2

Title: Method of manufacturing a part with a high quality surface finish and complex internal geometry

Abstract:
A structural member having an internal geometry capable of receive an object and substantially seamless outer surfaces, and that is obtainable by a method that includes providing several small plates, welding together the small plates, removing the weld residue, and polishing an outer surface of the structural member to achieve a certain desired visual effect. A middle plate, or several middle plates, may be positioned between a first plate and a second plate. The middle portion occupied by the middle plates includes an opening, cavity, and/or channel. The opening, cavity, and/or channel may receive a cable from an electronic device, or house a component. The plates and the opening, cavity, and/or channels between the plates, generally have a small form factor, and accordingly, require an assembly process to create the opening, cavity, and/or channels rather than using traditional drilling and/or milling techniques.

Claims:
What is claimed is: 
     
       1. A method for assembling a structural member that includes a channel for a component, the method comprising:
 positioning inner layers between a first outer layer and a second outer layer, wherein the inner layers include a first inner layer having a first opening and a second inner layer having a second opening that is aligned with the first opening so that the first and second openings define the channel that is capable of receiving the component; and 
 welding the inner layers to the first and second outer layers by directing a laser beam at a respective outer surface of at least one of the first or second outer layer such that respective interface surfaces of the first and second outer layers are welded to the inner layers along a path generally corresponding to a contour of the channel, wherein the first and second outer layers are generally parallel to the respective interface surfaces. 
 
     
     
       2. The method according to  claim 1 , further comprising:
 placing a third inner layer below the first and second inner layers, wherein the third inner layer includes a third opening that is aligned with the first or second opening. 
 
     
     
       3. The method according to  claim 1 , further comprising:
 removing any weld mark on the respective outer surface that is caused by welding the respective interface surfaces of the first and second outer layers to the inner layers. 
 
     
     
       4. The method according to  claim 2 , wherein the channel comprises:
 a first channel portion formed in the first inner layer; and 
 a second channel portion formed in the second inner layer. 
 
     
     
       5. The method according to  claim 4 , wherein the second channel portion comprises a diagonal channel portion. 
     
     
       6. The method according to  claim 1 , wherein the laser beam forms a weld through at least one of the first or second outer layers. 
     
     
       7. The method according to  claim 1 , wherein the first outer layer and the second outer layer are free of openings. 
     
     
       8. A method of forming a structural member having a generally seamless surface finish and a cavity, the method comprising:
 placing central layers between first and second outer layers such that the central layers contact a first interface surface of the first outer layer and a second interface surface of the second outer layer, wherein the central layers include a first central layer having a first opening and a second central layer having a second opening that is aligned with the first opening such that the first and second openings define the cavity; and 
 directing a laser beam along an outer surface of the first or second outer layer to weld the central layers to the first and second outer layers, wherein the outer surface is generally parallel to the first and second interface surfaces. 
 
     
     
       9. The method according to  claim 8 , wherein the central layers and the first and second outer layers are characterized as having a substantially identical outer lengthwise dimension. 
     
     
       10. The method according to  claim 8 , further comprising:
 placing a third central layer below the first inner layer and the second inner layer, and wherein the third central layer comprises a third opening aligned with the first opening or the second opening to define the cavity. 
 
     
     
       11. The method of  claim 8 , wherein the first and second central layers have a generally equal amount of thickness. 
     
     
       12. The method of  claim 8 , further comprising:
 mechanically removing any weld mark on the outer surface of the first or second outer layer that is caused by welding respective interface surfaces of the first or second outer layers to the central layers. 
 
     
     
       13. The method of  claim 1 , wherein the first and second inner layers are characterized as having a generally equal amount of thickness. 
     
     
       14. The method of  claim 8 , wherein the first and second outer layers are characterized as having a generally equal amount of thickness. 
     
     
       15. The method of  claim 8 , wherein the cavity has a diagonal shape.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 61/884,901, filed on Sep. 30, 2013, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The described embodiments relate to methods for manufacturing a metallic part having a complex internal geometry and a high quality surface finish. 
     BACKGROUND 
     In the ongoing development of small personal computerized products such as laptops, tablets and smart phones, the casings or enclosures that organize, secure and protect the electronic components have also experienced significant transformation in response to the continuous pressure to reduce the size and weight of these structures. In many situations, the ongoing reductions have pushed the size of the individual structural pieces below that which can be easily or economically mass produced using conventional manufacturing techniques. At the same time, structural members that were previously enclosed within the casing have been moved to exterior positions where the aesthetics and appearance of the member become a concern. 
     Consequently, a need exists for improved methods for reliably producing small structural members that also meet the exterior aesthetic and design requirements of the overall product. It is towards such a manufacturing method that the present disclosure is directed. 
     SUMMARY 
     In one aspect, a method for forming a part having a complex internal geometry and a cosmetic exterior surface is described. The method may include forming a first feature through a surface of at least one of a plurality of metallic layers, the plurality of metallic layers may define the part, the plurality of metallic layers may each have a length substantially greater than a thickness. The method may also include joining the plurality of metallic layers together. The first formed feature may define a first cavity having the complex internal geometry within the part. 
     In another aspect, a structural member may be formed by the process of welding a plurality of layers together is described. The plurality of layers may define the structural member, the structural member may have a first cavity. The process of forming the structural member may also include removing a residual portion of the welding on an outer peripheral portion of the structural member. The process of forming the structural member may also include polishing the outer peripheral portion. 
     In another aspect, a method of forming a structural member having a plurality of metallic layers and a cavity extending through the plurality of metallic layers is described. The method may include a means for bonding the plurality of metallic layers. The plurality of metallic layers may include a first metallic layer having a dimension less than remaining plurality of metallic layers. The method may further include a means for positioning the first metallic layer to define the cavity. The cavity may extend from a first end of the structural member to a second end of the structural member. The second end may be different from the first end. 
     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: 
         FIGS. 1A-1E  are perspective schematic views of a plurality of metallic plates that together illustrate a method for making a metallic part, in accordance with one representative embodiment of the present disclosure; 
         FIG. 2  is a flowchart depicting a method for making a metallic part, in accordance with another representative embodiment; 
         FIGS. 3A-3C  are perspective schematic views of the making of a metallic part from a plurality of metallic plates, in accordance with yet another representative embodiment; 
         FIGS. 4A-4C  are perspective schematic views of the making of a metallic part from a plurality of metallic plates, in accordance with yet another representative embodiment; and 
         FIGS. 5A-5C  are perspective schematic views of the making of a metallic part from a plurality of metallic plates, in accordance with yet another representative embodiments. 
     
    
    
     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. 
     Traditional methods for creating a cavity or opening through a metal or plastic substrate include a machining operation (such as milling or drilling). Of course, the dimensions of the cavity are less than the face of the substrate. Accordingly, when the face of the substrate to be machined is relatively small, for example, 10 millimeters (“mm”), a circular cavity is may have a diameter of, for example, 4 mm. The diameter of the cavity generally corresponds to the diameter of the drilling tool. Generally, the maximum depth-to-diameter (of the drilling tool) ratios for drilling are 6:1. In the example above, a 4-mm diameter drilling tool may be able to drill to a maximum depth of 24 mm. In rare cases, the ratio may be increased to 8:1 creating a corresponding drilling depth of 32 mm. Issues arise when the desired cavity in the substrate exceed the maximum depth-to-diameter ratios. 
     This detailed description provides an alternate method for creating a cavity in a structure. The lengthwise dimension of the structure may be on the order of several hundred millimeters. Rather than drill a cavity into structures, this detailed description describes a method of stacking several layers of material, with a middle portion having smaller dimensions than a portion above the middle portion and a portion below the middle portion thereby leaving the structure with a cavity of any desired length. It would be appreciated by one of skill in the art that it would be difficult, if not impossible, to machine a solid substrate using conventional tooling and manufacturing techniques, especially in the small sizes described. 
       FIGS. 1-5  show several representative embodiments of a method for making metallic parts have complex internal geometries and a substantially seamless surface finish. The term “seamless” as used throughout this detailed description and in the claims refers to a surface having no traces of a seam and/or joint resulting from joining one or more structures together, where joining structures may include welding one or more plates together thereby leaving traces of weld material and/or weld marks. This method can provide several significant advantages and benefits over other methods for making metallic parts with internal geometries. The recited advantages are not meant to be limiting in any way, however, as one skilled in the art will appreciate that other advantages may be realized upon practicing the present disclosure. In addition, it is also to be appreciated that certain aspects, embodiments, implementations or features of the described methods may be used separately or in different combinations, and that other uses and applications may also be possible and considered to fall within the scope of the present disclosure. 
       FIGS. 1A-1E  illustrate schematic views of a plurality of plates undergoing a manufacturing process. In some embodiments, the plates could be aluminum, titanium, or plastic. In the embodiment shown in  FIGS. 1A-1E , the plates are stainless steel, and in particular, stainless steel grade 304 (austenitic). In other embodiments, stainless steel grade 410 could be used. The illustrations have been sequentially organized to illustrate, in accordance with one representative embodiment, a method for making a final, polished configuration  80  (shown in  FIG. 1E ) having a channel  82  and a substantially seamless surface  86 . Throughout the illustrations, like structures are identified with like reference numerals throughout the figures. 
       FIG. 1A  is an exploded view showing individual components of the structure. A first plate  10  and a second plate  20  form a bottom and top surface, respectively, for the metallic part. In some embodiments, first plate  10  and second plate  20  may vary in length  15  and/or width  17 . In the embodiment shown in  FIG. 1A , first plate  10  and second plate  20  both have a substantially identical length  15  and width  17 . Length  15  of first plate  10  and second plate  20  are approximately 40 millimeters, but length  15  of first plate  10  and second plate  20  could vary. In other words, length  15  of first plate  10  and second plate  20  could be longer or shorter to achieve a desired dimension for a path for a cable or wire (discussed below). Length  15  could be as long as 300 mm in some embodiments, and as short as 10 mm in other embodiments. First plate  10  and/or second plate  20  may have a thickness  19  approximately in the range of 2.5 mm to 6 mm. However, in some embodiments, thickness  19  could be 1 mm. Generally, the ratio of length  15  to thickness  19  is approximately within the range of 10:1 to 100:1. 
     Also, in some embodiments, first plate  10  has a greater thickness than that of second plate  20 . In other embodiments, second plate  20  has a greater thickness than that of first plate  10 . In the embodiment shown in  FIG. 1A , the thickness of first plate  10  is substantially identical to the thickness of second plate  20 . Also, first plate  10  and second plate  20  have a substantially uniform thickness. 
     Between first plate  10  and second plate  20  are a first center plate  30  and second center plate  34 . First center plate  30  and second center plate  34  may have a thickness approximately in the range as that of first plate  10  and second plate  20 . First center plate  30  and second center plate  34  may be configured to have at least one dimension different from that of first plate  10  and second plate  20 . For example,  FIG. 1A  shows both first center plate  30  and second center plate  34  having a width less than width  17  of first plate  10  and second plate  20 . Consequently, when first center plate  30  and second center plate  34  are spaced apart to align with the lengthwise surfaces of first plate  10  and second plate  20 , a channel  40  is formed. First center plate  30  and second center plate  34  may be made of the same materials as described for first plate  10  and second plate  20 . Also, in some embodiments, first center plate  30  could have a greater thickness than that of second center plate  34 , or vice versa. Accordingly, thickness of channel  40  could vary (that is, the thickness may be non-uniform). 
     Channel  40  is configured to allow objects to objects such as wires or cables to pass through channel  40 . A cable may have a diameter approximately in the range of 0.5 to 3 mm. As shown in  FIG. 1A , channel  40  has a wavelike configuration corresponding to wavelike configurations along an inner lengthwise dimension of first center plate  30  and second center plate  34 . The phrase “inner lengthwise dimension” as used throughout this detailed description and in the claims refers to the lengthwise dimension of first center plate  30  that directly faces a lengthwise direction of second center plate  34 , or vice versa. In other embodiments, first center plate  30  and second center plate  34  could be substantially linear inner lengthwise dimension. Still, in other embodiments, first center plate  30  could have a different inner lengthwise dimension than that of second center plate  34  in order to achieve a desired complex internal geometry for an object to pass through channel  40 . It should be understood that the geometry of channel  40  corresponds to the geometry first center plate  30  and second center plate  34 . Also, the thickness (or, vertical height) of channel  40  is substantially similar to that of first center plate  30  and second center plate  34 . 
       FIG. 1B  shows an engaged (vertically stacked) configuration  50  having first center plate  30  and second center plate  34  engaged with first plate  10  and second plate  20 . The outer lengthwise dimension (that is, the dimension facing away from channel  56 ) of first center plate  30  is aligned, or flush, with a first outer edge  52  of first plate  10 . Likewise, an outer lengthwise dimension of second outer edge is aligned, or flush, with a second outer edge of first plate  20 . This configuration allows the width of first center plate  30  plus the width of second center plate  34  plus the width of opening  58  to be substantially identical to width  57  of first plate  10  and second plate  20 . Further, this allows engaged configuration  50  to have a channel  56  extending through engaged configuration  50 . Channel  56  has an opening  58  at each widthwise dimension of engaged configuration  50 . Also, as shown in  FIG. 1B , the height  59  of the engaged configuration  50  is approximately 12 mm. However, in other embodiments, height  59  could be greater than or less than the embodiment shown. 
       FIGS. 1C-1D  illustrate the process of assembling first center plate  30  and second center plate  34  to first plate  10  and second plate  20 , thereby creating a welded configuration  60 .  FIG. 1C  shows the configuration as shown in  FIG. 1B , with several welding steps used to assemble the plates. A welding tool  70  is used to create the various welds of the welded configuration  60 . Welding tool  70  could be any tool having sufficient power to create a weld through the several stainless steel plates. In particular, the welding tool  70  can create a weld extending from an outer (top) surface  66  of a top plate, or second plate  20  (shown in  FIG. 1B ) to an opposite outer surface of a bottom plate, or first plate  10  (shown in  FIG. 1B ). In the embodiment shown in  FIG. 1C , welding tool  70  is a laser weld tool producing a laser beam  71  of sufficient strength to perform the necessary welds shown. In order to achieve a proper weld, welding tool  70  was moved at various distances, and accordingly, laser beam  71  contacted welded configuration  60  at various distances until a desired result was achieved. Further, the focal point of laser  71  may be adjusted to achieve a desired result. In other embodiments, diffusion bonding could be used instead of welding tool  70 . In particular, in some embodiments where titanium is used for plates, diffusion bonding is desirable to bond the various plates and create a desired visual effect. 
     As shown in  1 C, first welds  76  are performed on outer surface  66  of the top plate. In other embodiments, first weld  76  could be performed on an outer surface of first plate  10 . First welds  76  create a weld between the top plate and two plates (such as first center plate  30  and second center plate  34 ) disposed between the top plate and the bottom plate. In other words, first weld  76  is capable of welding the two middle plates to the top plate and the bottom plate in a single step. In order to achieve this result, it is empirically shown that power approximately in the range of 0.5 to 8.5 kilowatts (“kW”) could be used. In other embodiments, first welds  76  weld the middle plates to the top plate, and a subsequent weld is necessary on the outer surface of the bottom plate to weld the middle plates to the bottom plate. First weld  76  also corresponds to the non-linear path of a channel between the top plate and the bottom plate (for example, channel  40  shown in  FIG. 1A ). First welds  76  generally correspond to the shape of the channel such that first welds  76  engage the middle plates and does not engage the channel. The area free of welding due to a channel below the top plate (or conversely, above the bottom plate) is defined as  67 . 
       FIG. 1C  further shows a second welds  72  made along the lengthwise edge surfaces of the welded configuration  60 . Second welds  72  are configured to weld the middle plates to the top plates at outer edges of the plates. Although not shown for one of the middle plates, both middle plates receive a second weld  72  (for example, on a lengthwise side of first center plate  30  and second center plate  34  not shown). Third welds  62  may be made along the widthwise edge surfaces the welded configuration  60 . Although not shown for one of the middle plates, both middle plates receive a third weld  62  (for example, on a widthwise side of second center plate  34  not shown). Second welds  72  and third welds  62  are configured to create seam or joint such that first center plate  30  and second center plate  34  are further bonded with first plate  10  and second plate  20 . In some embodiments, second welds  72  may be continuous welds from one edge to an opposite edge. In other embodiments, spot welding could be used for second welds  72  and third welds  62 . For example, an initial portion of second welds  72  may be welded followed by subsequent second welds  72  to a subsequent portion. Similar alternatives for third welds  62  are also possible. These alternatives could be made due to considerations such as power of welding tool  70  and/or to avoid welding into openings, channels, or cavities. 
     It should be understood that first weld  76 , second weld  72 , and third weld  62  are not intended to denote a particular order of creating welds. Rather, any order of welding among first weld  66 , second weld  72  and third weld  62  could be used to achieve a desired result (such as alignment of the plates and/or efficiency of manufacturing). 
     Also shown in  FIG. 1C  are weld reinforcement mark, or simply weld mark, resulting from the various welds. First weld mark  77  corresponds to first weld  76 , second weld mark  73  corresponds to second weld  72 , and third weld mark  63  corresponds to third weld  62 . These weld mark may protrude in a distal direction with respect to the welded configuration  60 . 
     In order to achieve a desired cosmetic appeal, first weld mark  77 , second weld mark  73 , and third weld mark  63  may be removed. As shown in  FIG. 1D , a mechanical tool  78 , or simply tool, may be used to remove first weld mark  67 , second weld mark  72 , and third weld mark to create relatively smooth surfaces. Tool  78  could be any tool known in the art for removing weld mark or weld residue. In the embodiment shown in  FIG. 1D , tool  78  is a grinding wheel. While grinding wheel  78  can remove first weld mark  77 , second weld mark  73 , and third weld mark  63 , there still may be noticeable traces of welded regions left behind. For example,  FIG. 1D  shows outer surface  66  of the top plate showing traces of first weld  76 . Similarly, traces of second weld  72  are also visible after tool  78  removed a portion of second weld  72 . 
     To further achieve the desired cosmetic appeal or visual effect,  FIG. 1E  shows the welded configuration of  FIG. 1D , further having a polishing step to remove any visible traces of first weld mark  67 , second weld mark  73 , and third weld mark  63 . The final polished configuration  80  includes a channel  82  configured to receive a cable connected to an electronic device or a circuit. The finished polished surfaces, denoted as  86 , shows the desired exterior finish. This can provide the finished structural member with the appearance of being formed from a single piece of metallic material. 
       FIG. 2  is a flowchart depicting a method  100  for making a structural member having a complex internal geometry and substantially seamless outer surfaces, in accordance with the embodiment previously shown. The method includes a first step  110  of obtaining or procuring a first plate, a second plate, and one or more center plates, with each plate having a length that is substantially greater than the thickness of the plate. As previously stated, in some embodiments, the plates could be made of stainless steel. The method also includes another step  112  of assembling together the first plate, the center plates, and the second plate to form a structural member having an internal geometry and peripheral faces having at least two side seams. The internal geometry can be any number of complex internal geometries. The method further includes a step  114  of welding the center plates to the top plate and the bottom plate. The center plates have dimensions such that a channel is formed when the center plates are attached to the top plate and the bottom plate. Also, a further step  116  is used to mechanically remove weld residue from the peripheral faces to form smooth peripheral surfaces without visible seams. The smooth peripheral surfaces can include a polishing step. Also, the mechanical removal may be performed without the use of heat treatment. For example, a grinding process may remove traces of seams. 
       FIGS. 3A-3C  show perspective views of forming another structural member  280  (welded and polished in  FIG. 3C ) from a plurality of plates. While previous embodiments disclose a structural member having two center plates between a first plate and a second plate, other embodiments may have three or more center plates. Still, other embodiments could include center plates (between a first plate and second plate) lying on top of one another. In the embodiment shown in  FIGS. 3A-3C , first center plate  230 , second center plate  234 , and third center plate  238  are all disposed between first plate  210  and second plate  220 . First plate  210 , second plate  220 , first center plate  230 , second center plate  234 , and third center plate  238  may be made from the same materials and have substantially similar dimensions (in terms of length, width, and thickness) as that of the plates described in the previous embodiments. 
     Also, the previous embodiments disclosed a channel  40  have a substantially co-planar path (with respect to first center plate  30  and second center plate  34 ), the channel in a structural member may not be co-planar with just one plate or plates. This may require various channels that are non-continuous from one end of a plate to another end of a plate. For example,  FIG. 3A  shows first center plate  230  having first channel  246  having an opening on a widthwise surface of first center plate  230  and extending only partially into first center plate  230 . As shown, first channel  246  includes a curved surface connecting two straight, parallel surfaces. In other embodiments, first channel  246  could have dimensions suitable to achieve a desired path to receive, for example, a cable. Third center plate  238  includes third channel  248  having similar dimensions to that of first channel  246 . However, first channel  246  and third channel  248  may be different in other embodiments. For example, first channel  246  could be greater than third channel  248 , or vice versa. Also, while first channel  246  is disposed near an edge of first center plate  230 , third channel  248  is disposed near an edge that is diagonal to edge near first channel  248 . The edge near first channel  246  is opposite to the edge near third channel  248  in both a lengthwise and widthwise manner. In other words, if first channel  246  and third channel  248  were disposed on the same center plate, a diagonal line could be required to connect first channel  246  to third channel  248 . In other embodiments, first channel  246  and third channel  248  are not diagonal with respect to one another. 
     Second center plate  234  includes second channel  217  that, as shown, is generally diagonal. When first center plate  230  is engaged and aligned with second center plate  234 , and when second plate  234  is engaged and aligned with third center plate  238  (as shown in  FIG. 3B ), at least a portion of second channel  217  is disposed over first channel  246  and at least a portion of second channel  217  is disposed under third channel  248 . Such a configuration may produce a path having both a substantially horizontal component and a substantially vertical component (see channel  282 , in  FIG. 3C ). In this manner, a cable may extend through first channel  246  in a substantially horizontal manner, then extend through second channel  217  in a diagonal (but vertically upward) manner, and then extend through third channel  248  in a substantially horizontal manner. Of course, the cable could take the opposite path (for example, by first extending through third channel  248 ). It would be appreciated by one of skill in the art that it would be difficult, if not impossible, to machine a solid substrate using conventional tooling and manufacturing techniques, especially in the small sizes described, to create a cavity having a substantially non-linear path. 
       FIG. 3A  also illustrates first center plate  230 , second center plate  234 , and third center plate  238  each having multiple openings  242  disposed within the plates. Openings  242  in third center plate  238  are disposed over openings  242  in second center plate  234 , which in turn, are disposed in openings  242  over first center plate  230  such that when the plates engage one another (see  FIG. 3B ), the opening  242  create a cavity having a thickness substantially similar to the combined thickness of first center plate  230 , second center plate  234 , and third center plate  238  (see cavity  284 , in  FIG. 3C ). As shown, the cavity is generally elliptical. However, in other embodiments, the cavity could be any cavity necessary to achieve a desired shape (for example, to house a particular component). Also, in other embodiments, there could be three or more openings  242  disposed in each of first center plate  230 , second center plate  234 , and third center plate  238 . Still, in other embodiments, there may be only one opening  242  disposed in first center plate  230 , second center plate  234 , or third center plate  238 . Alternatively, there could be openings  242  limited to, for example, first center plate  230  and second center plate  234 . 
       FIG. 3B  illustrates a similar welding operation previously described used to weld plates together along the face as well as the edges. Because additional center plates are used, additional power may be supplied to a welding tool in order to weld from outer surface  267  of second plate  220  vertically down to first plate  210 . Alternatively, the welding tool may, for example, piecewise weld second plate  220  to third center plate  238  and second center plate  234 , followed by welding first plate  210  to first center plate  230  and second center plate  234 . It will be understood that the welding tool will avoid any openings (for example, opening  242  and first channel  246 ) while welding the plates together. Generally, there are no welds within any opening.  FIG. 3B  shows first welds  276  on outer surface  267  with a resultant first weld mark  277 , second welds  272  on lengthwise edges with resultant second weld mark  273 , and third welds  262  with resultant third weld mark  263 . Although not shown, all center (or middle) plates receive a second weld  272  (for example, on a lengthwise side of second center plate  234  not shown). Also, although not shown, all middle plates receive a third weld  262  (for example, on a widthwise side of second center plate  234  not shown). First weld mark  277 , second weld mark  273 , and third weld mark  263  may be removed by any means described in the previous embodiments. As with the previous embodiments, the denotation of a first weld, a second weld, and a third weld are not intended to specify a particular order of welds made to the structural member. 
       FIG. 3C  illustrates a subsequent polishing process performed to structural member  280  having a substantially seamless surface  286 . The polishing process used to remove any remaining traces of welds may be performed by any means described in the previous embodiments. 
     In some embodiments, channels may extend through the (combined) structural member in a substantially vertical direction rather than a substantially horizontal direction. For example,  FIGS. 4A-4C  illustrate an embodiment of a structural member  380  (welded and polished in  FIG. 4C ) with such a configuration. As shown in  FIG. 4A , center plate  330  is positioned between first plate  310  and second plate  320 . Each of first plate  310 , second plate  320 , and center plate  330  include at least one opening  318 . Opening  318  could be a shape having curved surfaces or having three, four, or five or more sides. In the embodiment shown in  FIG. 4A , opening  318  is generally circular.  FIG. 4A  also illustrates first plate  310  having an opening  318  intending to align with opening  318  of center plate  330 , and also second plate  320  having an opening  318  intending to align with opening  318  of center plate  330 , thereby creating a cavity  388  through the structural member (see  FIG. 4C ). In this manner, cavity  388  may receive a cable in a substantially vertical direction. Alternatively, an object (for example, a small screw) could be inserted into cavity  388  in order to secure structural member  380  to another structural (for example, a printed circuit board). First plate  310 , second plate  320 , and center plate  330  may be made from the same materials and have substantially similar dimensions (in terms of length, width, and thickness) as that of the plates described in the previous embodiments. 
     Also,  FIG. 4A  shows center plate  330  having opening  318  and opening  342 , but no corresponding openings  318  and opening  342  within first plate  310  or second plate  320 , respectively. This configuration may be used, for example, to store particular components with openings  318  and opening  34  of center plate  330 . In embodiments where plates are electrically conductive, the components may be electrically connected to components external to the structural member  380 . Also, components within openings  318  and/or opening  342  may be shielded (in some cases, mechanically and/or electrically) from other components. Also, first plate  310 , second plate  320 , and center plate  330  may be shaped in a form different from a substantially rectangular shape. For example,  FIG. 4A  shows first plate  310 , second plate  320 , and center plate  330  each being “C-shaped” and each having six lateral surfaces. In this manner, structural member  380  may be configured to fit in a particular shape that structural member could not otherwise fit into. It should be understood that first plate  310 , second plate  320 , and center plate  330  could be shaped in a manner such that structural member  380  achieves a desired shape for a particular purpose. 
       FIGS. 4B and 4C  illustrate the welding and polishing procedures, respectively, described in the previous embodiments. In  FIG. 4B , welded member  360  includes first welds  376  on outer surface  367  includes first weld mark  367 , followed by a second welds  377  on a lengthwise edge  370 , and a third welds  362  on widthwise edge  363 . Although not shown, center plate  330  receives a second weld  377  on the lengthwise side of center plate  330  not shown. Also, although not shown, center plate  330  receives a third weld  362  on the widthwise side of center plate  330  not shown. Collectively, it should be understood that the C-shaped configuration of the embodiment shown in  FIGS. 4A-4C  receive second weld  377  and third weld  362  around the entire outer perimeter of welded member  360 . As with the previous embodiments, the denotation of a first weld  376  a second weld  377 , and a third weld  362  are not intended to specify a particular order of welds made to the structural member. Again, care is taken to avoid welding into openings  318  and/or openings  342 .  FIG. 4C  shows the final, polished structural member  380  having a substantially seamless surface  386 . 
     Some embodiments may include a pair of plates having a particular channel, opening and/or cavity on one surface. For example, in the embodiment shown in  FIGS. 5A and 5B , first plate  410  includes a channel  442  extending lengthwise through first plate  410  from one edge of first plate  410  to another, opposite edge of first plate  410 . First plate  410  further includes cavity  444 . In other embodiments, first plate  410  may include two or more cavities  444 . Second plate  420 , on the other hand, is free of any openings, channels, and/or cavities. In other embodiments, second plate  420  may include openings, channels, and/or cavities corresponding (or complimentary) to first plate  410 . Yet, in other embodiments, second plate  420  may include openings, channels, and/or cavities distinct from that of first plate  410 . Also, first plate  410  and second plate  420  may be made from the same materials and have substantially similar dimensions (in terms of length, width, and thickness) as that of the plates described in the previous embodiments. 
       FIGS. 5B and 5C  illustrate the welding and polishing procedures, respectively, described in the previous embodiments. In  FIG. 5B , welded member  460  includes first welds  476  on outer surface  466  includes first weld mark  467 , followed by a second welds  477  on a lengthwise edge  476 , and a third welds  462  on widthwise edge  463 . As with the previous embodiments, the denotation of a first weld  476 , a second weld  477 , and a third weld  462  are not intended to specify a particular order of welds made to the structural member. Again, care is taken to avoid welding into channel  442  and cavity  444 .  FIG. 5C  shows the final, polished structural member  480  having a substantially seamless surface  486 . 
     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 target 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: 20140317
Publication Date: 20190507
Grant Date: 20190507
Priority Date: 20130930
Inventors: THEOBALD, MATTHEW S.
MONTPLAISIR, SARAH J.
Assignee: APPLE INC
CPC Classifications: [{"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B7/05", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K26/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/12292", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B15/01", "inventive": true, "first": true, "tree": "[]"}, {"code": "B32B2307/718", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B2457/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B3/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "B32B7/045", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23K26/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T428/12292", "inventive": false, "first": false, "tree": "[]"}, {"code": "B32B15/01", "inventive": true, "first": true, "tree": "[]"}, {"code": "B32B2307/718", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 52740445