INTERLOCKING FLEXIBLE SEGMENTS FORMED FROM A RIGID MATERIAL

• US 20130216740A1
• Filed: 02/15/2013
• Published: 08/22/2013
• Est. Priority Date: 02/16/2012
• Status: Abandoned Application

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Russell-Clarke, Peter N., Nasher, Michael S.
• Application Number:
  US13/768,943
• Publication Number:
  US 20130216740A1
• Time in Patent Office: Days
• US Class Current: 428/33
• CPC Class Codes: B21D 31/04 Expanding other than provided for in groups B21D1/00 - B21D28/00, e.g. for making expanded metal B21D47/00 takes precedence; enlarging tube ends B21D41/02
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B29C 53/063 combined with folding
• CPC Class Codes: B65D 85/00 Containers, packaging elements or packages, specially adapted for particular articles or materials B65D71/00, B65D83/00 take precedence; hand implements or travelling equipment A45C; cosmetic or toiletry equipment A45D; packages for surgical knives, scalpels or blades therefor A61B17/3215; containers specially adapted for medical or pharmaceutical purposes A61J1/00; paint cans B44D3/12; oil cans F16N3/04; containers for carrying small arms F41C33/06; packaging of ammunition or explosive charges F42B39/00; containers for record carriers, specially adapted for cooperation with the recording or reproducing apparatus G11B23/00
• CPC Class Codes: G06F 1/1616 with folding flat displays, e.g. laptop computers or notebooks having a clamshell configuration, with body parts pivoting to an open position around an axis parallel to the plane they define in closed position
• CPC Class Codes: G06F 1/1681 Details related solely to hinges hinge details related to the transmission of signals or power are classified in G06F1/1683
• CPC Class Codes: Y10T 428/13 Hollow or container type article [e.g., tube, vase, etc.]

Abstract

A method for creating a flexible portion or bending portion within a rigid structure. The method can also be used for creating a flexible structure from a rigid material. The method includes providing a substantially rigid material, such as, but not limited to, metals, alloys, hard plastics, and the like, and selectively removing portions of the rigid material defining a geometric pattern in the rigid material. A bending radius of the flexible portion is defined by the geometric pattern. The rigid structure may be used to create an enclosure, a cover for an electronic device, one or more hinges, or the like.

Claims

1. A method for creating a flexible portion in a rigid material, comprising:

providing a substantially rigid material; and

selectively removing portions of the rigid material defining a geometric pattern in the rigid material, the geometric pattern defining the flexible portion;

wherein

a bend radius of the flexible material is defined by the geometric pattern.

2. The method of claim 1, wherein the geometric pattern comprises:

at least two flex apertures; and

at least two sidewalls bordering and defining the flex apertures;

wherein

the sidewalls are angled between a first surface of the rigid material and a second surface of the rigid material.

3. The method of claim 1, wherein the flexible structure includes a first flexible portion having a first bend radius and a second flexible portion having a second flexible portion.

4. The method of claim 1, wherein selectively removing portions of the rigid material comprises at least one of heating the rigid material with a laser or using electrical discharge machining.

5. The method of claim 1, wherein at least one surface of the rigid material is substantially planar.

6. The method of claim 1, wherein the rigid material is a three-dimensional shape.

7. A method for creating an enclosure for an electronic device comprising:

providing a rigid material; and

removing sections of the rigid material to create a geometric pattern.

8. The method of claim 7, wherein the operation of providing a rigid material further comprises metal molding the rigid material.

9. The method of claim 7, wherein removing sections of the rigid material is performed by a laser cutting device.

10. An enclosure formed of a substantially rigid material comprising:

a first plurality of flex apertures defined within the rigid material along a first row;

a second plurality of flex apertures defined within the rigid material along a second row;

wherein

the second row is positioned below the second row;

the first plurality of flex apertures are misaligned with the second plurality of flex apertures such that a first end of each of the first plurality of flex apertures is in a different vertical plane from a first end of each of the second plurality of flex apertures; and

when a bending force is applied to one of the first row or the second row, the first plurality of flex apertures and the second plurality of flex apertures vary in shape or dimension, allowing the rigid material to bend.

11. The enclosure of claim 10, wherein the first plurality of flex apertures and the second plurality of flex apertures are substantially diamond shaped.

12. A housing of a substantially rigid material, comprising:

a first plurality of interlocking features defined within the rigid material;

a second plurality of interlocking features defined within the rigid material; and

a plurality of flex apertures defined between the first plurality of interlocking features and the second plurality of interlocking features to separate the first plurality of interlocking features from the second plurality of interlocking features;

wherein

the first plurality of interlocking features is movable relative to the second plurality of interlocking features.

13. The housing of claim 12, wherein the first plurality of interlocking features and the second plurality of interlocking features are substantially frustum shaped.

14. The housing of claim 12, wherein each of the first plurality of interlocking features include at least one sidewall, wherein the at least one sidewall changes in angular orientation from a first surface of the rigid material to a second surface of the rigid material.

15. The housing of claim 14, wherein each of the second plurality of interlocking features include at least one sidewall, wherein the at least one sidewall changes in angular orientation from the first surface of the rigid material to a second surface of the rigid material.

16. A method of manufacturing a flexible component, comprising:

providing a substantially rigid material; and

removing portions of the rigid material to create a plurality of flex apertures, wherein the flex apertures are defined by interlocking features adjacent each other and spaced apart by the flex apertures;

wherein

each interlocking feature has at least one sidewall and an angle of the sidewall determines a radial bend of the rigid material; and

the rigid material is non-cylindrical.

17. The method of claim 16, wherein the rigid material is planar.

18. The method of claim 16, wherein a geometric pattern is defined in the rigid material by the plurality of flex apertures.

19. The method of claim 18, wherein a first side of the rigid material has a first geometric pattern and the second side of the rigid material has a second geometric pattern.

20. The method of claim 16, wherein removing portions of the rigid material is done by one of a multi-axis laser or electrical discharge machining.