# US 8,570,729 B2 · Seamless insert molding techniques > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,570,729 B2 - Document ID: US8570729B2 - Status: Granted - Kind: B2 - Application number: 13/620,015 - Filed: 2012-09-14 - Published: 2013-08-22 - Granted: 2013-10-29 - Earliest claimed: 2008-08-19 - Assignees: Apple Inc. - Applicants: Christopher Prest; Eric Wang; Bradley J. Hamel; Phillip Michael Hobson - Inventors: Christopher Prest; Eric Wang; Bradley J. Hamel; Phillip Michael Hobson - Web page: https://patentgrep.com/patent/US8570729B2 ## CPC - H05K 5/0217: {Mechanical details of casings (covers, lids, hoods or members for covering apertures H05K5/03)} - B29C 45/14336: {Coating a portion of the article, e.g. the edge of the article (B29C45/14573 and B29C45/14598 take precedence)} - B29C 45/14639: {for obtaining an insulating effect, e.g. for electrical components} - B29C 45/14434: {Coating brittle material, e.g. glass (B29C45/14377, B29C45/14418 take precedence)} - B29K 2705/00: Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts - Y10T 29/49002: Electrical device making - Y10T 29/4998: Combined manufacture including applying or shaping of fluent material - Y10T 428/13: Hollow or container type article [e.g., tube, vase, etc.] - Y10T 428/1307: Bag or tubular film [e.g., pouch, flexible food casing, envelope, etc.] - Y10T 428/131: Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.] - Y10T 428/1321: Polymer or resin containing [i.e., natural or synthetic] - Y10T 428/1352: Polymer or resin containing [i.e., natural or synthetic] - H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS - 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) - 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 - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## 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 ### Claim 1 A housing suitable for a portable computing device, comprising: a single piece first body formed of a first material and comprising a first external surface having first edges that define a first opening, the first external surface transitioning to first side walls having a first set of bonding surfaces; and a single piece second body formed of a second material and comprising a second external surface, the second external surface transitioning to second side walls, the housing formed by directly bonding the single piece second body in a non-solid form to the first set of bonding surfaces that is subsequently hardened into a solid form to create the single piece second body that in cooperation with the first body defines a cavity suitable for carrying operational components of the portable computing device, wherein directly bonding the single piece second body to the single piece first body creates an overall external surface of the housing from the first and second external surfaces and the first and second sidewalls that is tactilely seamless. ### Claim 2 (depends on 1) The housing as recited in claim 1, wherein the first set of bonding surfaces include at least one attachment feature. ### Claim 3 (depends on 2) The housing as recited in claim 2, wherein the attachment feature comprises a second opening configured to receive at least some of the second material in non-solid form, wherein the subsequent hardening locks the second body to the first body. ### Claim 4 (depends on 2) The housing as recited in claim 2, wherein the attachment feature comprises a protrusion configured to be surrounded by at least some of the second material in non-solid form, wherein the subsequent hardening locks the second body about the protrusion of the first body. ### Claim 5 (depends on 1) The housing as recited in claim 1, wherein subsequent to bonding of the first body to the second body the first opening is configured to accept operational components of the portable computing device during an assembly operation. ### Claim 6 (depends on 1) The housing as recited in claim 1, wherein the first and second materials are different. ### Claim 7 (depends on 1) The housing as recited in claim 1, wherein the first opening has a size and shape in accordance with a display of the portable computing device. ### Claim 8 (depends on 1) The housing as recited in claim 1, wherein the second body further comprises an accessory opening. ### Claim 9 (depends on 8) The housing as recited in claim 8, wherein a camera module is disposed through the accessory opening. ### Claim 10 A method for forming a portable computing device housing, comprising: obtaining a single piece first body formed of a first material and comprising a first external surface having first edges that define a first opening, the first external surface transitioning to first side walls having a first set of bonding surfaces; injection molding a molten molding material directly to a first body formed of a first material and comprising a first external surface having first edges that define a first opening, the first external surface transitioning to first side walls having a first set of bonding surfaces, wherein the molten molding material contacts the first body along the first set of bonding surfaces; cooling the molten molding material until it hardens into a solid single piece second body comprising a second external surface, the second external surface transitioning to second side walls and cooperating with the single piece first body to define a cavity suitable for carrying operational components of the portable computing device, wherein the direct bonding of the single piece second body to the single piece first body creates an overall external surface of the housing from the first and second external surfaces and the first and second sidewalls that is tactilely seamless. ### Claim 11 (depends on 10) The method as recited in claim 10, further comprising: placing the first body within a mold cavity prior to bonding the molten molding material to the first body. ### Claim 12 (depends on 11) The method as recited in claim 11, wherein the molten molding material is bonded directly to the first body as part of an injection molding process. ### Claim 13 (depends on 10) The method as recited in claim 10, further comprising installing a camera module through an accessory opening disposed in the second body. ### Claim 14 (depends on 13) The method as recited in claim 13, wherein the interface between the two component is between a glass lens of the camera module and the trim ring, the trim ring formed from injection molded plastic. ### Claim 15 (depends on 10) The method as recited in claim 10, wherein the bonding the molten molding material to the first body includes the molten molding material flowing about a plurality of bonding features disposed along the first set of bonding surfaces. ### Claim 16 A housing of a portable electronic device, comprising: a single piece first body formed of a first material and comprising a first external surface transitioning to first side walls having a first set of bonding surfaces; and a single piece second body formed of a second material and comprising a second external surface having first edges that define a first opening, the second external surface transitioning to second side walls, the housing formed by directly bonding the single piece second body in a non-solid form to the first set of bonding surfaces that is subsequently hardened into a solid form to create the single piece second body that in cooperation with the first body defines a cavity suitable for carrying operational components of the portable electronic device, wherein directly bonding the single piece second body to the single piece first body creates an overall external surface of the housing from the first and second external surfaces and the first and second sidewalls that is tactilely seamless. ### Claim 17 (depends on 16) The housing as recited in claim 16, wherein the first set of bonding surfaces include at least one attachment feature configured to lock the first and second body together subsequent to solidification of the second body. ### Claim 18 (depends on 17) The housing as recited in claim 17, wherein the first body further comprises an accessory opening through which a camera module can be disposed. ### Claim 19 (depends on 16) The housing as recited in claim 16, wherein the portable electronic device is a mobile phone. ### Claim 20 (depends on 16) The housing as recited in claim 16, wherein the first material is a different material than the second material.