Methods and Systems for Integrally Trapping a Glass Insert in a Metal Bezel

• US 20090017263A1
• Filed: 07/11/2008
• Published: 01/15/2009
• Est. Priority Date: 07/12/2007
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Yeates, Kyle H.
• Granted Patent: US 8,738,104 B2
• Time in Patent Office: Days
• US Class Current: 428/167
• CPC Class Codes: B22D 19/00 Casting in, on, or around objects which form part of the product B22D23/04 takes precedence; alumino-thermic welding B23K23/00; coating by casting molten material on the substrate C23C6/00
• CPC Class Codes: B22D 19/04 for joining parts
• CPC Class Codes: C03C 27/02 by fusing glass directly to metal
• CPC Class Codes: G06F 1/1656 Details related to functional adaptations of the enclosure, e.g. to provide protection against EMI, shock, water, or to host detachable peripherals like a mouse or removable expansions units like PCMCIA cards, or to provide access to internal components for maintenance or to removable storage supports like CDs or DVDs, or to mechanically mount accessories mounting of accessories to a computer display G06F1/1607; display hoods G06F1/1603; cooling arrangements for portable computers G06F1/203
• CPC Class Codes: H05K 7/02 Arrangements of circuit components or wiring on supporting structure
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 428/2457 Parallel ribs and/or grooves

Abstract

Methods and apparatus for creating an overall assembly formed from a transparent member and a metal member are disclosed. According to one aspect of the present invention, a method includes positioning a transparent member in a mold configured for insertion molding, and providing a liquid metal into the mold. The method also includes hardening the liquid metal in the mold. Hardening the liquid metal includes binding the metal to the transparent member to create the integral assembly.

Claims

7. A method for forming an integral assembly, the method comprising:

positioning a transparent member in a mold;

using a metal injection molding (MIM) process to provide metal around the transparent member; and

shrinking the metal at least partially around the transparent member, wherein shrinking the metal binds the metal to the transparent member to create the integral assembly.

8. The method of claim 7 wherein the transparent member is glass and the liquid metal is LiquidMetal.

9. The method of claim 7 wherein the transparent member includes at least one attachment feature, the attachment feature being positioned approximately at an edge of the transparent member.

10. The method of claim 9 wherein the at least one attachment feature includes at least one channel.

11. The method of claim 9 wherein the at least one attachment feature includes a chamfer.

12. The method of claim 7 wherein the MIM process includes centering the transparent member relative to the metal.

13. The method of claim 7 wherein shrinking the metal includes shrinking the metal by between approximately twenty percent and approximately thirty percent.

14. A method comprising:

applying at least one layer of a compliant material to an edge of a transparent member; and

binding the compliant material to an edge of a metal member arrangement, wherein binding the compliant material to the edge of the metal member arrangement creates an overall assembly.

15. The method of claim 14 further including:

applying at least one layer of the compliant material to the metal member arrangement, wherein the edge of the metal member arrangement is an edge of the at least one layer of the compliant material.

16. The method of claim 14 wherein the metal member arrangement is a bezel and the transparent member is a glass window.

17. The method of claim 14 wherein the compliant material is a gasket.

18. The method of claim 17 wherein the transparent member includes a first channel and the metal member arrangement includes a second channel, the gasket being positioned at least partially in the first channel and at least partially in the second channel.

20. The method of claim 14 wherein the compliant material is one selected from a group including a silicon, a rubber, a thermoplastic elastomer, and poron.

19. The method of claim 19 wherein the gasket is arranged to provide a biasing force between the metal member arrangement and the transparent member.

21. An apparatus comprising:

a transparent member, the transparent member including a first channel;

a metal member, the metal member including a second channel; and

a compliant material, the compliant material being arranged in the first channel and the second channel, wherein the compliant material couples the transparent member to the metal member.

22. The apparatus of claim 21 wherein the transparent member is glass and the compliant member is formed from one selected from a group including a silicon, a rubber, a thermoplastic elastomer, and poron.

23. An electronic device comprising:

an assembly, the assembly including a metal member and a transparent member with substantially no voids disposed therebetween, the metal member and the transparent member cooperating to define an exterior portion of the electronic device; and

at least one electronic element, the at least one electronic element being arranged to be at least partially covered by the assembly.

1. A method for forming an integral assembly, the method comprising:

positioning a transparent member in a mold;

providing a liquid metal into the mold; and

hardening the liquid metal, wherein hardening the liquid metal includes binding the liquid metal to the transparent member to create the integral assembly.

2. The method of claim 1 wherein the transparent member is glass and the liquid metal is LiquidMetal.

3. The method of claim 1 wherein the transparent member includes at least one retaining feature, the retaining feature being positioned at an edge of the transparent member, the retaining feature being arranged to facilitate binding between the liquid metal and the transparent member.

4. The method of claim 3 wherein the at least one retaining feature is a protrusion or a void.

5. The method of claim 1 wherein a thermal expansion rate of the liquid metal is approximately equal to a thermal expansion rate of the transparent member.

6. The method of claim 1 wherein hardening the liquid metal in the mold forms a bezel that holds the transparent member.

24. The electronic device of claim 23 wherein the transparent member is glass.

25. The electronic device of claim 24 wherein the metal member is a bezel.

25-1. The electronic device of claim 23 wherein the electronic device is a cellular phone device.