Seamless Insert Molding Techniques

• US 20100048257A1
• Filed: 08/19/2008
• Published: 02/25/2010
• Est. Priority Date: 08/19/2008
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Prest, Christopher, Hamel, Bradley, Wang, Erik, Hobson, Phillip Michael
• Granted Patent: US 8,346,183 B2
• Time in Patent Office: Days
• US Class Current: 455/575.100
• CPC Class Codes: B29C 45/14336 Coating a portion of the article, e.g. the edge of the article B29C45/14573 and B29C45/14598 take precedence
• CPC Class Codes: B29C 45/14434 Coating brittle material, e.g. glass B29C45/14377, B29C45/14418 take precedence
• CPC Class Codes: B29C 45/14639 for obtaining an insulating effect, e.g. for electrical components
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: H05K 5/0217 Mechanical details of casings covers, lids, hoods or members for covering apertures H05K5/03
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 428/13 Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/1307 Bag or tubular film [e.g., pouch, flexible food casing, envelope, etc.]
• CPC Class Codes: Y10T 428/131 Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
• CPC Class Codes: Y10T 428/1321 Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1352 Polymer or resin containing [i.e., natural or synthetic]

Abstract

Methods and apparatus for using an insert molding process to form a tactilely seamless overall part from component parts that are made from different materials are disclosed. According to one aspect of the present invention, a housing includes a first part formed from a first material and a second part formed from a second material that is of a different type than the first material. The first part includes a first external surface and a first bonding surface, and the second part includes a second external surface and a second bonding surface. The second bonding surface can be integrally bonded to the first bonding surface so that the first external surface and the second external surface form a gap-free overall surface.

Claims

1. A housing comprising:

a first part, the first part being formed from a first material, the first part including a first external surface and a first bonding surface; and

a second part, the second part being formed from a second material, the second material being a different type of material than the first material, the second part including a second external surface and a second bonding surface, the second bonding surface being integrally bonded to the first bonding surface, wherein the first external surface and the second external surface form a gap-free overall surface.

2. The housing of claim 1 wherein the first material is a non-plastic material and the second material is a plastic material.

3. The housing of claim 2 wherein the first material is metal.

4. The housing of claim 2 wherein the first material is glass.

5. The housing of claim 1 wherein the second bonding surface is integrally bonded to the first bonding surface using an injection molding process.

6. An apparatus comprising:

at least one electrical component; and

a housing, the housing being arranged at least partially around the at least one electrical component, the housing including a first housing portion and a second housing portion, wherein the first housing portion is formed from a first material and includes a first external surface and a first bonding surface, and wherein the second housing portion is formed from a second material and includes a second external surface and a second bonding surface, the second material being a different type of material than the first material, the second bonding surface being integrally bonded to the first bonding surface such that the first external surface and the second external surface form a gap-free overall external surface.

7. The apparatus of claim 6 wherein the second material is a plastic material and the first material is a non-plastic material.

8. The apparatus of claim 7 wherein the first material is metal.

9. The apparatus of claim 7 wherein the first material is glass.

10. The apparatus of claim 9 wherein the first housing portion and the second housing portion form a housing component, and

wherein the housing further includes a third housing portion, the housing component being arranged to be inserted in the third housing portion.

11. The apparatus of claim 6 wherein the apparatus is a handheld electronic device.

12. The apparatus of claim 11 wherein the handheld electronic device comprises a mobile phone.

13. The apparatus of claim 6 wherein the second bonding surface is integrally bonded to the first bonding surface using an injection molding process.

14. The apparatus of claim 6 wherein the first housing portion is a bezel.

15. A method of fabricating a housing, the method comprising:

obtaining a first part, the first part being formed from a first material, the first part including a first external surface and a first bonding surface; and

directly bonding a second part to the first bonding surface of the first part, the second part being formed from a second material, the second material being a different type of material than the first material,

wherein directly bonding the second part to the first part creates an overall external surface of the housing from the first external surface and a second external surface of the second part, the overall external surface being gap-free.

16. The method of claim 15 wherein the directly bonding of the second part to the first bonding surface of the first part includes creating a bond interface between the second part and the first bonding surface, and wherein an edge of the bond interface is part of the overall external surface.

17. The method of claim 15 wherein the directly bonding of the second part to the first bonding surface of the first part includes providing the second material in a non-solid form and hardening the second material into a solid form to create the second external surface.

18. The method of claim 15 wherein the first material is a non-plastic material and the second material is a plastic material.

19. The method of claim 18 wherein the first material is metal.

20. The method of claim 18 wherein the first material is glass.