# US 9,882,302 B2 · Enclosures having a seamless appearance

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- Number: US 9,882,302 B2
- Document ID: US9882302B2
- Status: Granted
- Kind: B2
- Application number: 15/282,750
- Filed: 2016-09-30
- Published: 2017-03-30
- Granted: 2018-01-30
- Earliest claimed: 2015-09-30
- Assignees: Apple Inc.
- Applicants: Apple Inc.
- Inventors: Alexander M. Kwan; Cesar Lozano Villarreal; Siri Amrit Ramos; Xuyang Zhang; Peter A. Dvorak
- Web page: https://patentgrep.com/patent/US9882302B2

## CPC

- H01R 13/504: different pieces being moulded, cemented, welded, e.g. ultrasonic welding, or swaged together
- B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)}
- B29C 66/1162: {Single bevel to bevel joints, e.g. mitre joints}
- B29C 66/1222: {comprising at least a lapped joint-segment}
- B29C 66/1224: {comprising at least a butt joint-segment}
- B29C 66/1226: {comprising at least one bevelled joint-segment}
- B29C 66/1248: {Interpenetrating groove joints (interpenetrating fingered joints B29C66/139)}
- B29C 66/1282: {comprising at least one overlap joint-segment}
- B29C 66/12821: {comprising at least two overlap joint-segments}
- B29C 66/1284: {comprising at least one butt joint-segment}
- B29C 66/1286: {comprising at least one bevelled joint-segment}
- B29C 66/53461: {joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies}
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29C 66/73921: {characterised by the materials of both parts being thermoplastics}
- H01R 13/665: {with built-in electronic circuit (H01R13/70, H01R13/719 take precedence)}
- H01R 27/02: for simultaneous co-operation with two or more {dissimilar} counterparts
- H01R 43/18: for manufacturing bases or cases for contact members
- B29C 66/124: {Tongue and groove joints}
- B29C 66/8322: {Joining or pressing tools reciprocating along one axis}
- B29L 2031/3481: {Housings or casings incorporating or embedding electric or electronic elements}
- B29L 2031/36: Plugs, connectors, or parts thereof
- H01R 13/5045: {different pieces being assembled by press-fit}
- H01R 13/521: {Sealing between contact members and housing, e.g. sealing insert}
- H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- 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)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

An enclosure for an AC to DC adapter has a continuous and apparently seamless exterior surface. The enclosure includes a housing and a cap that are joined by a pair of weld joints. One weld is formed on an interior portion of the enclosure providing strength and one weld joint is formed on the exterior surface providing a seamless appearance for the enclosure.

## Claims

### Claim 1

An enclosure for an electronic assembly, the enclosure having a seamless exterior appearance and comprising:
a housing comprising a bottom wall and at least one side wall extending from the bottom wall, the at least one side wall comprising a beveled end portion having a curved tip;
a cap comprising a protrusion coupled to the beveled end portion of the housing, wherein the cap, the bottom wall, and the at least one side wall define a cavity in which the electronic assembly is disposed;
a first weld joint formed between the protrusion and the beveled end portion of the housing and a second weld joint formed between the housing and the cap, wherein the first and the second weld joints are separated by a non-interference region; and
at least two electrical prongs extending through the bottom wall and electrically coupled to the electronic assembly.

### Claim 2 (depends on 1)

The enclosure of claim 1, wherein the cap is coupled to the at least one side wall with a first and a second weld joint.

### Claim 3 (depends on 1)

The enclosure of claim 1 wherein the housing has a generally rectangular cross-section and the at least one side wall comprises four sidewalls.

### Claim 4 (depends on 1)

The enclosure of claim 1 wherein the housing has a round cross-section and the at least one side wall consists of a single sidewall.

### Claim 5 (depends on 2)

The enclosure of claim 2, wherein the first and the second weld joints are separated by a distance and have a non-interference region between them.

### Claim 6 (depends on 5)

The enclosure of claim 5, wherein the beveled end portion and the protrusion define the non-interference region with a pair of sloped surfaces.

### Claim 7 (depends on 6)

The enclosure of claim 6, wherein the pair of sloped surfaces are both at an angle between 30 and 40 degrees.

### Claim 8 (depends on 2)

The enclosure of claim 2, wherein the first weld joint is formed between the protrusion and the beveled end portion.

### Claim 9 (depends on 2)

The enclosure of claim 2 wherein the second weld joint is formed within an interference region disposed between the side wall and the cap.

### Claim 10 (depends on 2)

The enclosure of claim 2, wherein the first and the second weld joints are ultrasonically formed welds.

### Claim 11 (depends on 1)

The enclosure of claim 1, wherein at least a portion of a top surface of the cap is proud with respect to the curved tip of the beveled end portion.

### Claim 12 (depends on 1)

The enclosure of claim 1, wherein a top surface of the cap is formed with a matte surface.

### Claim 13

A method of forming an enclosure having a seamless exterior appearance for an electronic assembly, the method comprising:
forming a housing having a bottom wall and at least one side wall extending from the bottom wall, the at least one side wall comprising a beveled end portion having a curved tip, and the bottom wall being formed around at least two electrical prongs extending through the bottom wall;
disposing the electronic assembly within the housing such that the electrical assembly is electrically coupled to the at least two electrical prongs;
positioning a cap comprising a protrusion on the housing; and
coupling the protrusion to the beveled end portion with a first joint and a second joint that are separated from each other by a non-interference region, wherein the cap, the bottom wall, and the at least one side wall define a cavity in which the electronic assembly is disposed.

### Claim 14 (depends on 13)

The method of claim 13, wherein the protrusion is coupled to the beveled end portion with a first and a second joint.

### Claim 15 (depends on 14)

The method of claim 14 wherein the first and the second joints are formed by ultrasonic welding.

### Claim 16 (depends on 15)

The method of claim 15 wherein the second joint is formed by shear forces acting on an interference region disposed between the side wall and the cap.

### Claim 17 (depends on 15)

The method of claim 15 wherein the second joint is formed by compression forces acting on an interference region disposed between the side wall and the cap.

### Claim 18 (depends on 14)

The method of claim 14 wherein the first joint is formed by ultrasonic welding and the second joint is formed with an adhesive.

### Claim 19 (depends on 14)

The method of claim 14, wherein the first and the second joints are separated by a distance and have a non-interference region between them.

### Claim 20 (depends on 19)

The method of claim 19, wherein the beveled end portion and the protrusion define the non-interference region with a pair of sloped surfaces.

### Claim 21 (depends on 20)

The method of claim 20, wherein the pair of sloped surfaces are both at an angle between 30 and 40 degrees.

### Claim 22 (depends on 13)

The method of claim 13, wherein at least a portion of a top surface of the cap is proud with respect to the curved tip of the beveled end portion.