# US 11,077,593 B2 · Housings for electronic devices > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,077,593 B2 - Document ID: US11077593B2 - Status: Granted - Kind: B2 - Application number: 16/278,022 - Filed: 2019-02-15 - Published: 2019-06-13 - Granted: 2021-08-03 - Earliest claimed: 2007-07-13 - Assignees: Apple Inc. - Applicants: Apple Inc. - Inventors: Douglas Weber; Stephen P. Zadesky; Stephen Brian Lynch - Web page: https://patentgrep.com/patent/US11077593B2 ## CPC - B29C 45/1657: {using means for adhering or bonding the layers or parts to each other (mechanical anchoring B29C37/0082)} - B23K 26/382: by boring - B29C 37/0082: {Mechanical anchoring (B29C66/303 takes precedence)} - B29C 45/14311: {using means for bonding the coating to the articles (B29C45/14795 takes precedence)} - B29C 45/1671: {with an insert} - C23F 1/00: Etching metallic material by chemical means (manufacture of printing surfaces B41C; manufacture of printed circuits H05K) - C23F 1/16: Acidic compositions (C23F1/42 takes precedence) - B29C 45/14344: {Moulding in or through a hole in the article, e.g. outsert moulding} - B29C 2045/14327: {anchoring by forcing the material to pass through a hole in the article} - B29K 2055/02: ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers - B29K 2069/00: Use of PC, i.e. polycarbonates {or derivatives thereof}, as moulding material - B29K 2705/00: Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts - B29L 2031/3481: {Housings or casings incorporating or embedding electric or electronic elements} - B32B 2355/02: ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers - B32B 2369/00: Polycarbonates - B32B 2457/00: Electrical equipment - Y10T 428/13: Hollow or container type article [e.g., tube, vase, etc.] - Y10T 428/1352: Polymer or resin containing [i.e., natural or synthetic] - Y10T 428/1355: Elemental metal containing [e.g., substrate, foil, film, coating, etc.] - Y10T 428/24008: including fastener for attaching to external surface - Y10T 428/24273: including aperture - Y10T 428/24521: with component conforming to contour of nonplanar surface - Y10T 428/31678: Of metal - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - C23F: NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE (working metal by laser beams B23K26/00; desurfacing by applying flames B23K7/00; working of metal by electro-erosion B23H; producing decorative effects by removing surface material, e.g. by engraving, by etching, B44C1/22; electrolytic etching or polishing C25F); INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25 - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Methods and apparatus for applying internal features or complex mechanical structures to a surface of a metal part are disclosed. According to one aspect of the present invention, a method for creating an assembly that includes a substrate and a molded piece involves obtaining the substrate, and forming at least one binding feature on a surface of the substrate. The method also includes molding on a surface of the binding feature and the surface of the substrate. Molding on the surface of the binding feature and the surface of the substrate mechanically binds the molded piece to the substrate. ## Claims ### Claim 1 A housing for a mobile phone, comprising: a metal part defining: a cosmetic exterior surface of the housing; a bonding region internal to the housing; and a plurality of recesses formed into the metal part along the bonding region, a recess of the plurality of recesses defined by: an opening in the bonding region of the metal part; and a chamber in communication with the opening, the opening being narrower than the chamber to define an undercut; and a molded plastic piece contacting the metal part and having portions extending into each recess of the plurality of undercut recesses to affix the molded plastic piece to the metal part; wherein a thickness of a first portion of the metal part defined between a surface of the chamber and the cosmetic exterior surface of the housing is less than a thickness of a second portion of the metal part adjacent the recess. ### Claim 2 (depends on 1) The housing of claim 1, wherein the metal part and the molded plastic piece cooperate to define a smooth surface. ### Claim 3 (depends on 1) The housing of claim 1, wherein; the metal part is a first metal part; and the molded plastic piece is further affixed to a second metal part. ### Claim 4 (depends on 1) The housing of claim 1, wherein the recess of the plurality of recesses is defined in cross-section by at least one curved surface. ### Claim 5 (depends on 1) The housing of claim 1, wherein the plurality of recesses are formed by chemical etching. ### Claim 6 (depends on 1) The housing of claim 1, wherein the recess of the plurality of recesses is defined by a machined recess surface. ### Claim 7 (depends on 1) The housing of claim 1, wherein the molded plastic piece fills the chamber and the opening. ### Claim 8 A mobile phone, comprising: a housing comprising: a metal part defining: an exterior surface of the housing; and a void machined into the metal part and defining: an opening; and a chamber in communication with the opening, the opening being narrower than the chamber to define an undercut; and a unitary molded plastic piece filling the void and engaging the undercut to retain the unitary molded plastic piece to the metal part; and a plurality of electronic components contained within the housing; wherein a first portion of the metal part that defines the void is thinner than a second portion of the metal part adjacent the void. ### Claim 9 (depends on 8) The mobile phone of claim 8, wherein the metal part and the unitary molded plastic piece cooperate to define a smooth surface. ### Claim 10 (depends on 8) The mobile phone of claim 8, wherein: the void defines: a first void region; and a second void region contiguous with the first void region; the second void region is undercut with respect to the first void region; and the unitary molded plastic piece occupies the first void region and the second void region. ### Claim 11 (depends on 8) The mobile phone of claim 8, wherein the metal part is formed of stainless steel or aluminum. ### Claim 12 (depends on 8) The mobile phone of claim 8, wherein the unitary molded plastic piece is formed from a nonconductive plastic. ### Claim 13 (depends on 8) The mobile phone of claim 8, wherein: the void is a first void; the metal part further defines a second void; and the unitary molded plastic piece further fills the second void. ### Claim 14 A handheld electronic device, comprising: a housing structure, comprising: a metal part defining: at least a portion of an internal volume of the handheld electronic device; an exterior surface of the handheld electronic device; and a recess defined by: an opening in the metal part; and a chamber in communication with the opening, the opening being narrower than the chamber to define and undercut; and a unitary plastic piece having a portion formed within the recess and retained to the metal part via the undercut, the unitary plastic piece defining a portion of an internal surface of the housing structure; and a plurality of electronic components within the internal volume; wherein a first portion of the metal part that defines the recess is thinner than a second portion of the metal part adjacent the recess. ### Claim 15 (depends on 14) The handheld electronic device of claim 14, wherein the unitary plastic piece defines a screw boss having an opening configured to receive a screw. ### Claim 16 (depends on 14) The handheld electronic device of claim 14, wherein the recess is formed by chemical etching. ### Claim 17 (depends on 14) The handheld electronic device of claim 14, wherein the recess is formed by machining. ### Claim 18 (depends on 17) The handheld electronic device of claim 17, wherein: the metal part defines a plurality of additional recesses; and the unitary plastic piece extends into the plurality of additional recesses.