Sealing housing via interlocking housing edges to prevent water ingress

Abstract

Aspects of sealing of a housing are described. In some examples, the housing includes a first housing member having a first edge. The first edge includes a first set of edge features. A second housing member having a second edge includes a second plurality of edge features configured to interlock with the first set of edge features. When the first set of edge features is interlocked with the second set of edge features, a gap between the first protruding feature in the first edge and the second protruding feature and the third protruding feature in the second edge overlaps.

Description

Technical Field

[0001] This application relates to systems and methods for sealing enclosures, and more particularly to sealing enclosures against water ingress via interlocking enclosure edges. Background Art

[0002] Enclosures help protect the items within from various physical, electrical, moisture, and other environmental damages. Gaskets, when properly positioned along the edges of the enclosure assembly of an electronic device, can prevent moisture such as water droplets from entering the enclosure and damaging moisture-sensitive components located within.

[0003] However, one drawback of the enclosures of existing electronic devices during production, maintenance, and servicing is the gasket. Gaskets are vulnerable parts that are prone to assembly errors and failures over time and repeated assembly cycles. The gasket may be squeezed or cut, may fail to stay in place when the electronic device is opened, or may be completely lost in some cases. Thus, an electronic device that is considered to have a certain level of water resistance may actually be vulnerable to water ingress due to gasket failure.

[0004] Another drawback of existing enclosures is that the connection parts of the enclosures are fragile and easily damaged. The connecting edges of the enclosures may be damaged due to daily use, impacts, and the connection and disconnection of the connecting edges. Another drawback of existing enclosures is that existing enclosures may have short and direct water intrusion paths. If water enters the seam between the connecting edges of an existing enclosure, the water will quickly pass through and enter the interior of the enclosure.

[0005] As described above, there is a need in the art for an enclosure design that can provide a stronger sealing structure between the connecting edges of an enclosure. Summary of the Invention

[0006] One embodiment of the present disclosure recites a system that includes: a first enclosure piece having a first edge that includes a first plurality of protruding features; and a second enclosure piece having a second edge that includes a second plurality of protruding features configured to interlock with the first plurality of protruding features, wherein when the first plurality of protruding features interlock with the second plurality of protruding features, a first protruding feature among the first plurality of protruding features overlaps a gap between a second protruding feature and a third protruding feature among the second plurality of protruding features.

[0007] At least one technical advantage of the disclosed technology over the prior art is that, using the disclosed technology, a design that uses interlocking edges to prevent water intrusion can prevent water from entering. The technology extends the path of water intrusion, prevents water intrusion, and strengthens the connection location of the interlocking edges. The technology also provides a stronger and more durable housing, increasing the resistance to squeezing forces compared to housings that use other types of protrusions or connections. These technical advantages provide one or more technical improvements over prior art methods. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In order to understand in a manner that can detail the above features of the various embodiments, a more specific description of the inventive concept briefly outlined above can be made with reference to the various embodiments, some of which are illustrated in the drawings. However, it should be noted that the drawings only illustrate typical embodiments of the inventive concept and should not be considered in any way to limit the scope, and there are other equivalent embodiments.

[0009] Figure 1A is a diagram showing an electronic device according to various embodiments;

[0010] Figure 1B is a perspective view of a multi-piece housing according to various embodiments;

[0011] Figure 2A is an exploded view of an interlocking edge feature according to various embodiments;

[0012] Figure 2B is a perspective view of an interlocking edge feature according to various embodiments;

[0013] Figure 2C is an external view of an interlocking edge feature according to various embodiments;

[0014] Figure 2D is an internal view of an interlocking edge feature according to various embodiments;

[0015] Figure 3 is an exploded view of a part of a multi-piece housing according to an embodiment;

[0016] Figure 4 is a set of side views and cross-sectional views of an interlocking edge feature according to various embodiments;

[0017] Figure 5 is a set of cross-sectional views of an interlocking edge feature according to various embodiments;

[0018] Figure 6A is an exploded side view of an interlocking edge feature according to various embodiments;

[0019] Figure 6Bis a side view of an interlocking edge feature according to various embodiments; and

[0020] Figure 7 is a flow chart of method steps for configuring a multi-piece housing according to various embodiments. DETAILED DESCRIPTION

[0021] In the following description, numerous specific details are set forth to provide a more thorough understanding of the various embodiments. However, it will be apparent to one of ordinary skill in the art that the inventive concept may be practiced without one or more of these specific details.

[0022] Figure 1A is a diagram showing an electronic device 100 having a multi-piece housing 110 according to various embodiments. As shown, the electronic device 100 includes, but is not limited to, a multi-piece housing 110 and one or more moisture-sensitive components 120 disposed within the multi-piece housing 110. The multi-piece housing 110 includes, but is not limited to, two or more housing pieces 112 and 114. The two or more housing pieces 112 and 114 each include, but are not limited to, at least a portion of an interlocking edge feature 116. The interlocking edge feature 116 includes, but is not limited to, a protruding feature and a recessed feature. The recessed or indented edge feature can accommodate the protruding edge feature. In some examples, the protruding edge feature is firmly fitted into the recessed edge feature through an engineering fit such as a clearance fit, a transition fit, and / or an interference fit. In some examples, protrusions, ridges, and other elements on the protruding edge feature and / or the recessed edge feature contribute to the secure closure of the multi-piece housing 110.

[0023] The electronic device 100 can be any device or system that includes one or more moisture-sensitive components 120. For example, in some embodiments, the electronic device 100 can be a product or system configured for outdoor operation and / or operation in a humid environment. Examples of such products or systems include, but are not limited to, lighting devices, control panels or other user interfaces, sensing devices, and / or the like. Examples of the moisture-sensitive component 120 include, but are not limited to, wires, lighting elements or bulbs, printed circuit boards, moisture-absorbing materials ( For example , paper), corrosion-susceptible materials, and / or the like.

[0024] As shown, the multi-piece housing 110 includes two or more housing pieces 112 and 114, each housing piece including a subset of the interlocking edge feature 116. In some embodiments, the interlocking edge feature 116 can provide water resistance equal to or better than the IP54 rating. Referring to Figures 2A to 2D and Figure 3Figures 0 through 6 illustrate and describe detailed examples of the interlocking edge feature 116. In some embodiments, the materials of the housing members 112 and 114 are selected to further enhance the water resistance of the multi-piece housing 110. In such embodiments, the housing members 112 and 114 may be formed of one or more hydrophobic materials. Hydrophobic materials include, but are not limited to, polymers, acrylonitrile butadiene styrene (ABS), polycarbonate, nylon, fiberglass, and combinations thereof. Some hydrophobic materials are treated, textured, and / or coated to provide hydrophobicity. In some embodiments, the housing members 112 and 114 are held together by one or more mechanical fasteners (such as screws), protrusions, or other features. The mechanical fasteners, protrusions, and other features may form an integral part of the multi-piece housing 110 or may be separate components.

[0025] Figure 1B is a perspective view of a multi-piece housing 110 according to various embodiments. The illustrated multi-piece housing 110 includes, but is not limited to, two or more housing members 112 and 114. The housing members 112 and 114 include, but are not limited to, one or more fastener features 118.

[0026] In Figure 1B the illustrated embodiment, the multi-piece housing 110 is implemented as a yoke of an external lighting device. The yoke implementation shown in FIG. 1 enables a light element (not shown) to rotate about two axes, including axis A and axis B. In the illustrated example, axis A is orthogonal to axis B. However, as discussed, the multi-piece housing 110 may form any kind of housing for a product or system configured for external operation and / or operation in a wet environment.

[0027] Upon assembly, the multi-piece housing 110 includes two halves corresponding to the housing members 112 and 114 that form a seam along the outer side of the connection between the housing members 112 and 114. Figure 1B The multiple locations in

[0028] Figure 2AA more detailed view of the interlocking edge features 116 included in the multi-piece housing 110 according to various embodiments. The interlocking edge features 116 include, but are not limited to, a portion 202 of the first housing piece of the multi-piece housing 110 and a portion 204 of the second housing piece of the multi-piece housing 110. The portion 202 includes, but is not limited to, one or more edge features 212, 214, 215. Additional edge features are shown but not numbered. The portion 204 includes, but is not limited to, one or more edge features 216 and 218. The first housing piece 112 includes a gap 220 between the edge features 212 and 214 and a gap 222 between the edge features 214 and 215. The edge features 212, 214, 215, 216, and 218 include protruding features that fit into corresponding recessed features on another piece of the multi-piece housing 110.

[0029] The interlocking edge features 116 are formed on the edge region of the portion 202 and on the edge region of the portion 204. Specifically, the edge features 212 and 214 are included on the edge region of the portion 202, and the edge features 216 and 218 are included on the edge region of the portion 204. According to various embodiments, the interlocking edge features 116 are configured such that the portion 202 and the portion 204 are assembled together. When the portion 202 and the portion 204 are assembled, the edge features 212, 214, 215, and other edge features of the portion 202 of the first housing piece interlock with the edge features 216, 218, and other edge features of the portion 204 of the second housing piece 114.

[0030] In addition, one or more protruding features on the portion 204 ( For example , the edge features 216, 218) overlap with the gap between two adjacent protruding features on the portion 202 ( For example , the edge features 212, 214, 215). For example, the edge feature 216 inserts into and fills the gap 220 between the edge features 212 and 214. The edge feature 218 inserts into and fills the gap 222 between the edge features 214 and 215. Similarly, one or more protruding features on the portion 202 ( For example , the edge feature 212) overlap with the gap (not visible) between two adjacent protruding features on the portion 204 ( For example , the edge features 216 and 218). For example, the edge feature 214 inserts into and fills the gap (not visible) between the edge features 216 and 218. The protruding features can be considered to protrude from the surface relative to the external (and / or internal) seams of the corresponding parts of the housing.

[0031] In this way, there is no short direct path for moisture to travel from the outer surface of the multi-piece housing 110 to the inner surface of the multi-piece housing 110 (e.g., via gaps 220 and 222). This is because for each gap formed between adjacent protruding features on the edge portion of one housing piece, the protruding features on the corresponding edge portion of the other housing piece block or overlap the gap. Thus, any water droplets on the outer surface of the multi-piece housing 110 that contact the seam between portion 202 and portion 204 are forced to enter the multi-piece housing 110 along a circuitous path from the outer surface and cannot directly pass through gap 220 into the interior of the multi-piece housing 110. A circuitous path is formed regardless of the direction from which water intrudes into the respective edge features. The circuitous path enables a gasketless watertight seal that prevents water intrusion and slows water intrusion such that the water can evaporate or dry before passing through the circuitous path. However, in other embodiments, a gasket seal can also be provided by the edge features ( For example , Figure 6A , Figure 6B ).

[0032] Figure 2B A perspective view of the multi-piece housing 110 in accordance with various embodiments is shown. The interlocking edge features 116 include, but are not limited to, portion 202 of the first housing piece of the multi-piece housing 110 and portion 204 of the second housing piece of the multi-piece housing 110. Portion 202 and portion 204 are connected using interlocking edge features 116 (not shown) to form an external seam and an internal seam (not shown). When portion 202 and portion 204 are connected, this forms a circuitous path 230 from the external seam to the interior of the multi-piece housing 110. Any water droplets on the outer surface of the multi-piece housing 110 that contact the external seam between portion 202 and portion 204 are forced to flow into the multi-piece housing 110 along the circuitous path 230 from the outer surface.

[0033] Figure 2C An external view of the multi-piece housing 110 in accordance with various embodiments is shown. The interlocking edge features 116 include, but are not limited to, portion 202 of the first housing piece and portion 204 of the second housing piece. Portion 202 and portion 204 are connected using interlocking edge features 116 (not shown) to form an external seam and an internal seam (not shown). The external seam forms a continuous line between portion 202 and portion 204. There may be a very small space or no space at the external seam between portion 202 and portion 204.

[0034] Figure 2DShows an internal view of a multi-piece housing 110 according to various embodiments. The interlocking edge feature 116 includes, but is not limited to, a portion 202 of a first housing piece and a portion 204 of a second housing piece. The portion 202 and the portion 204 are connected using an interlocking edge feature 116 (not shown), forming an internal seam and an external seam (not shown). The internal seam forms a serpentine or meandering line between the portion 202 and the portion 204. There may be a small gap at the internal seam between the portion 202 and the portion 204, which prevents mechanical interference and enables the external seam (not shown) to form a waterproof adjacent connection.

[0035] Figure 3 Is an exploded view of a portion of a multi-piece housing 110 according to an embodiment. The interlocking edge feature 116 includes, but is not limited to, a portion 302 of a first housing piece and a portion 304 of a second housing piece. The portion 302 includes, but is not limited to, gaps 322, 324, and 326. The portion 304 includes, but is not limited to, edge features 332, 334, and 336. The gaps 322, 324, and 326 are formed between adjacent protruding edge features on the edge of the portion 302 of the first housing piece. The edge features 332, 334, and 336 are formed on the edge of the portion 304 of the second housing piece. As shown, each of the gaps 322, 324, and 326 corresponds to the central portion of a protruding feature on the edge of the other housing piece. For example, the gap 322 corresponds to and is blocked by the central portion of the edge feature 332. The gap 322 corresponds to and is blocked by the central portion of the edge feature 334. The gap 326 corresponds to and is blocked by the central portion of the edge feature 336. The central portion provides a connection or transition between two parallel offset portions of the edge feature, forming a zigzag or serpentine cross-section of the edge feature 336, where the cross-section is taken at the plane formed by the external (and / or internal) seam.

[0036] Figure 4 Is a set of views of an interlocking edge feature 116 according to various embodiments. The various views include a separated side view 402, an interlocked side view 404, an interlocked cross-sectional view 406, a separated cross-sectional view 408, and a separated cross-sectional view 410. The interlocking edge feature 116 includes, but is not limited to, a portion 422 of a first housing piece and a second housing piece. When the portion 420 is connected to the portion 422, the overall housing has open spaces 430 and 432 between the portion 420 and the portion 422. The portion 420 includes an external seam edge feature 440 and edge features 462, 442, 464, 444, 466, and 446. The portion 422 includes an external seam edge feature 450 and edge features 452, 472, 454, 474, 456, 476.

[0037] The separated side view 402 shows an interlocking edge feature 116 formed by a portion 420 of the first housing member and a portion 422 of the second housing member. The portion 420 of the first housing member and the portion 422 of the second housing member are configured to interlock to provide a waterproof outer seam and a tortuous path to prevent water from entering the internal area. When the portion 420 and the portion 422 are interlocked, the outer seam edge feature 440 moves towards the outer seam edge feature 450 until they are in firm contact. The recessed edge feature can accommodate the protruding edge feature. For example, the edge features 464 and 474 are recessed edge features. The edge features 444 and 454 are protruding edge features. The edge feature 464 accommodates the edge feature 444, and the edge feature 474 accommodates the edge feature 454. The edge feature 444 is inserted into the edge feature 464, and the edge feature 454 is inserted into the edge feature 474.

[0038] The interlocking side view 404 shows the portion 420 and the portion 422, as well as the open spaces 430 and 433 between the portion 420 and the portion 422. The portion 420 of the first housing member and the portion 422 of the second housing member are shown as interlocked. The interlocked portions 420 and 422 provide a waterproof outer seam and a tortuous path to prevent water from entering the internal area. The open spaces 430 and 433 make the connection between the outer seam edge feature 440 of the portion 420 and the outer seam edge feature 450 of the portion 422 tighter. For example, measured from a plane corresponding to the connection between the outer seam edge feature 440 and the outer seam edge feature 450, a set of recessed or concave features in the second housing member is longer than the projection lengths of the edge features 442, 444, and 446. Therefore, the recessed features in the second housing member exceed the depth of accommodating the edge features 442, 444, and 446. Similarly, measured from a plane corresponding to the connection between the outer seam edge feature 440 and the outer seam edge feature 450, another set of recessed features or concave features in the first housing member is longer than the projection lengths of the edge features 452, 454, and 456. The recessed features in the second housing member exceed the depth of accommodating the edge features 452, 454, and 456.

[0039] The interlock cross-sectional view 406 corresponds to the cross-section A-A of the interlock side view 404. The interlock cross-sectional view 406 shows the external seam edge feature 440 and the edge features 442, 444, 446 of the portion 420. The central portion of the edge feature 442 fills the gap between the edge features 452 and 454. The gap between the edge features 452 and 454 extends in a direction perpendicular to the line along which the external seam is formed and within the plane formed by the face of the seam edge feature 450. The central portion of the edge feature 444 fills the gap between the edge features 454 and 456. The gap between the edge features 454 and 456 extends in a direction perpendicular to the line along which the external seam is formed and within the plane formed by the face of the seam edge feature 450. The central portion of the edge feature 454 fills the gap between the edge features 442 and 444. The gap between the edge features 442 and 444 extends in a direction perpendicular to the line along which the external seam is formed and within the plane formed by the face of the seam edge feature 440. The central portion of the edge feature 456 fills the gap between the edge features 444 and 446. The gap between the edge features 444 and 446 extends in a direction perpendicular to the line along which the external seam is formed and within the plane formed by the face of the seam edge feature 440. As can be seen from the various views, the edge features ensure that the path from the outside to the inside is serpentine, zigzag, or otherwise circuitous. The interlock technique (including the lateral or vertical extension of the central portion relative to the length of the seam) provides a stronger and more durable housing, increasing the resistance to squeezing forces compared to housings using other types of protrusions or connections.

[0040] The separated cross-sectional view 408 corresponds to the view of the portion 420 in the cross-section A-A of the interlock side view 404. The separated cross-sectional view 408 shows the external seam edge feature 440 and the edge features 462, 442, 464, 444, 466, and 446 of the portion 420. The gaps between the edge features 442, 444, 446 can be seen from this view. The edge features 462, 464, and 466 are recessed edge features that are shaped to receive and provide an engineered fit with the edge features 452, 454, and 456 of the portion 422. The shape of the edge feature 462 is complementary to the shape of the edge feature 452. The shape of the edge feature 464 is complementary to the shape of the edge feature 454. The shape of the edge feature 466 is complementary to the shape of the edge feature 456. The edge features 442, 444, and 446 are protruding edge features whose shapes are designed to be inserted into and provide an engineered fit with the edge features 472, 474, and 476 of the portion 422. The shape of the edge feature 442 is complementary to the shape of the edge feature 472. The shape of the edge feature 444 is complementary to the shape of the edge feature 474. The shape of the edge feature 446 is complementary to the shape of the edge feature 476.

[0041] The separated sectional view 410 corresponds to the view of the portion 422 in the section A-A of the interlocking side view 404. The separated sectional view 410 shows the edge features 452, 454, 456 of the portion 422 and the external seam edge feature 450. The gaps between the edge features 452, 454, 456 can be seen from this view. The edge features 452, 454, and 456 are protruding edge features, and their shapes are designed to be inserted into the edge features 462, 464, and 466 of the portion 420 and provide an engineering fit with them. The edge features 472, 474, and 476 are recessed edge features, which are shaped to accommodate the edge features 442, 444, and 446 of the portion 420 and provide an engineering fit with them.

[0042] As Figure 4 shown, when viewed in cross-section, the individual edge features of the portion 420 can have the same shape as the individual edge features of the opposing mating portion 422. For example, when viewed in section A-A, the edge features 442 (and 444) of the portion 420 correspond to the same shape as the edge features 454 (and 456) of the portion 422. In addition, when viewed in cross-section, the pattern formed by the edge features of the portion 420 can form the same pattern as the edge features of the opposing mating portion 422. However, in other examples, the pattern formed by the edge features of a part of the first housing member can form a first pattern, and the first pattern is complementary to a different second pattern formed by the edge features of a part of the second housing member that mates with the first housing member ( For example , Figure 5 , sectional view 508).

[0043] Figure 5A set of cross-sectional views of the interlocking edge feature 116 according to various embodiments. The set of cross-sectional views includes cross-sectional views 502, 504, 506, and 508. Cross-sectional view 502 shows the interconnected portion of the first housing member and the second housing member. The first housing member includes, but is not limited to, edge features 512 and 514. Edge feature 512 includes, but is not limited to, parallel elements 516 and 518 and a central portion 510. The second housing member includes, but is not limited to, edge features 522 and 524. Edge feature 522 includes, but is not limited to, parallel elements 526 and 528 and a central portion 520. Cross-sectional view 504 shows the interconnected portion of the third housing member and the fourth housing member. The third housing member includes, but is not limited to, edge features 532 and 534. Edge feature 532 includes, but is not limited to, parallel elements 536 and 538 and a central portion 530. The fourth housing member includes, but is not limited to, edge features 542 and 544. Edge feature 542 includes, but is not limited to, parallel elements 546 and 548 and a central portion 540. Cross-sectional view 506 shows the interconnected portion of the fifth housing member and the sixth housing member. The fifth housing member includes, but is not limited to, edge features 552 and 554. Edge feature 552 includes, but is not limited to, parallel elements 556 and 558 and a central portion 550. The sixth housing member includes, but is not limited to, edge features 562 and 564. Edge feature 562 includes, but is not limited to, parallel elements 566 and 568 and a central portion 560. Cross-sectional view 508 shows the interconnected portion of the seventh housing member and the eighth housing member. The seventh housing member includes, but is not limited to, edge feature 570. Edge feature 570 includes, but is not limited to, parallel elements 572, 574, and 576, and central portions 590 and 592. The eighth housing member includes, but is not limited to, edge features 582, 584, and 586.

[0044] Cross-sectional view 502 shows an example of the interlocking edge feature 116 having ninety-degree central portions 510 and 520. Edge feature 512 includes a central portion 510 connecting parallel elements 516 and 518. Edge feature 512 forms a protruding zigzag or serpentine shape that mates with a recessed edge feature and / or gap of the mating or opposing edge of the interlocking edge feature 116. Central portion 510 forms a ninety-degree angle with each of parallel elements 516 and 518 of edge feature 512. Edge feature 524 includes a central portion 520 connecting parallel elements 526 and 528. Edge feature 524 forms a protruding zigzag or serpentine shape that mates with a recessed edge feature of the mating edge of the interlocking edge feature 116 and / or gap. Central portion 520 forms a 90-degree angle with each of parallel elements 526 and 528 of edge feature 524.

[0045] Cross-sectional view 504 shows an example of the interlocking edge feature 116 having an obtuse angle formed ( For example, central portions 530 and 540 (greater than ninety degrees). The central portions form any angle relative to the parallel elements, including angles greater than, equal to, and less than ninety degrees. Edge feature 532 includes a central portion 530 connecting parallel elements 536 and 538. Edge feature 532 forms a protruding zigzag or serpentine shape that mates with the recessed edge feature and / or the clearance of the mating edge of the interlocking edge feature 116. Central portion 530 forms an angle greater than ninety degrees with each of parallel elements 536 and 538 of edge feature 532. Edge feature 544 includes a central portion 540 connecting parallel elements 546 and 548. Edge feature 544 forms a protruding zigzag or serpentine shape that mates with the recessed edge feature and / or the clearance of the mating edge of the interlocking edge feature 116. Central portion 540 forms an angle greater than ninety degrees with each of parallel elements 526 and 528 of edge feature 524.

[0046] Cross-sectional view 506 shows an example of an interlocking edge feature 116 having curved central portions 550 and 560. Edge feature 552 includes a central portion 550 connecting parallel elements 556 and 558. Edge feature 552 forms a protruding zigzag or serpentine shape that mates with the recessed edge feature and / or the clearance of the mating edge of the interlocking edge feature 116. Central portion 550 provides a curved connection between parallel elements 556 and 558 of edge feature 552. Edge feature 564 includes a central portion 560 connecting parallel elements 566 and 568. Edge feature 564 forms a protruding zigzag or serpentine shape that mates with the recessed edge feature and / or the clearance of the mating edge of the interlocking edge feature 116. Central portion 560 provides a curved connection between parallel elements 566 and 568 of edge feature 564.

[0047] Cross-sectional view 508 shows an example of an asymmetric complementary interlocking edge feature 116. The pattern formed by the edge feature 570 (and the recessed feature) of the seventh housing member forms a first pattern that is complementary to a different second pattern formed by the edge features 582, 584, and 586 (and the recessed feature) of a portion of the eighth housing member. The edge feature 570 includes a central portion 590 that connects parallel elements 572 and 574. The edge feature 570 also includes a central portion 592 that connects parallel elements 574 and 576. The edge feature 570 forms a protruding zigzag or serpentine shape that mates with the recessed edge features and / or gaps of the mating edges of the interlocking edge feature 116. The central portion 590 fills the gap between the edge features 582 and 584. The central portion of the edge feature 592 fills the gap between the edge features 584 and 586. Although the central portions 590 and 592 form a ninety-degree angle relative to the parallel elements, the central portions 590 and 592 can form any angle relative to the parallel elements, including angles greater than, equal to, and less than ninety degrees. The central portions 590 and 592 can additionally or alternatively provide a curved transition.

[0048] Figure 6A is an exploded side view of an interlocking edge feature 116 according to various embodiments. The interlocking edge feature 116 includes, but is not limited to, a portion 602 of the first housing member of the multi-piece housing 110 and a portion 604 of the second housing member of the multi-piece housing 110. The portions 602 and 604 form an external seam of the multi-piece housing 110. The portion 602 includes, but is not limited to, a gasket opening 612 in the external seam edge feature of the portion 602. The gasket opening 612 is shaped to hold a gasket 614. The portion 604 includes, but is not limited to, an external seam edge feature that forms an external seam with the external seam edge feature of the portion 602 when the interlocking edge feature 116 is interlocked. In this example, the portion 602 is configured to hold the gasket 614 against the plane of the external seam edge feature of the portion 604. In other examples, the external seam edge feature of the portion 604 includes a convex or concave shape that mates with or connects to the gasket 614 to form a waterproof seal. The gasket opening 612 and the gasket 614 can extend along the external seam edge feature of the portion 602, following the external seam.

[0049] Figure 6Bis a side view of the interlocking edge feature 116 according to various embodiments. The interlocking edge feature 116 includes, but is not limited to, a portion 602 of a first housing member of the multi-piece housing 110 and a portion 604 of a second housing member of the multi-piece housing 110. The portions 602 and 604 form a spire seam region 610 relative to an outer seam of the multi-piece housing 110. The spire seam region 610 enhances water resistance and prevents water intrusion into the multi-piece housing 110 by facilitating water runoff. When viewed from the outside of the multi-piece housing 110, the spire seam region 610 forms a curved concave structure on each of the portions 602 and 604. The portion 602 also includes a gasket opening in an outer seam edge feature, and the gasket opening is shaped to hold a gasket. In this example, the portion 602 holds the gasket against a plane of an outer seam edge feature of the portion 604. In other examples, the outer seam edge feature of the portion 604 includes a convex or concave shape that mates with the gasket. Although shown as a curved concave structure, when viewed from the outside ( See Figure 4 , the interlocking side view 404), the spire seam region 610 can also form a reverse angle at the outer seam. Although shown as part of a structure that includes a gasket, the spire seam region 610 can achieve a gasketless waterproof seal, reduce water pooling, prevent water intrusion, and slow water intrusion along the outer seam. For example, the gasket and the gasket opening in the outer seam edge feature of the portion 602 can be omitted.

[0050] Figure 7 is a flow chart of method steps for configuring a multi-piece housing 110 according to various embodiments. Although the method steps are described in connection with Figure 1A , Figure 1B and Figure 3 's multi-piece housing 110 and Figures 2A to 2D and Figure 4 to the interlocking feature 116 of FIG. 6, those of ordinary skill in the art will understand that any multi-piece housing 110, any interlocking feature 116, and any system configured to perform the method steps in any order are within the scope of the present invention.

[0051] As shown, method 700 begins at step 702, where a housing manufacturing system and / or process forms a first housing member of the multi-piece housing 110. The housing manufacturing system uses a process including one or more of molding, casting, printing, machining, vacuum forming, thermoforming, etc. to form the first housing member of the multi-piece housing 110. The first housing member of the multi-piece housing 110 includes an interlocking edge feature 116. The interlocking edge feature of the first housing member includes a protruding feature and / or a recessed feature. The protruding edge feature is configured to provide an engineered fit with a recessed edge feature of the second housing member. The recessed edge feature is configured to provide an engineered fit with a protruding edge feature of the second housing member.

[0052] At step 704, the housing manufacturing system and / or process forms a second housing piece of the multi-piece housing 110. The housing manufacturing system uses a process including one or more of molding, casting, printing, machining, vacuum forming, thermoforming, etc. to form the second housing piece of the multi-piece housing 110. The second housing piece of the multi-piece housing 110 includes interlocking edge features 116. The interlocking edge features 116 of the second housing piece include protruding features and / or recessed features. The protruding edge features are configured to provide an engineered fit with the recessed edge features of the first housing piece. The recessed edge features are configured to provide an engineered fit with the protruding edge features of the first housing piece.

[0053] At step 706, the housing manufacturing system and / or process positions moisture-sensitive components 120, such as electronic circuits, wires, lighting elements or bulbs, printed circuit boards, moisture-absorbing materials, corrosion-susceptible materials, and / or the like. The moisture-sensitive components 120 are positioned relative to and / or attached to at least one of the first housing piece and the second housing piece of the multi-piece housing 110.

[0054] At step 708, the housing manufacturing system and / or process seals the multi-piece housing 110. The process joins the interlocking edge features 116 of the first housing piece and the second housing piece to seal the multi-piece housing 110 and form a waterproof seal. The moisture-sensitive element 120 is sealed within the multi-piece housing 110.

[0055] In summary, the housing provides a waterproof seal. The housing uses at least a first housing piece and a second housing piece. The first housing piece includes a first edge having a first set of edge features. The second housing piece includes a second edge having a second set of edge features configured to interlock with the first set of edge features. When the first set of edge features interlocks with the second set of edge features, the gaps between a first protruding feature of the first set of edge features and a second protruding feature and a third protruding feature of the second plurality of edge features overlap.

[0056] At least one technical advantage of the disclosed technology over the prior art is that, with the disclosed technology, water ingress can be prevented by using a design with interlocking edges that prevent water ingress. The interlocking edges extend the path of water ingress, prevent water ingress, and strengthen the connection location of the interlocking edges. These technical advantages provide one or more technical improvements over prior art methods.

[0057] Aspects of the subject matter described herein are set forth in the following numbered clauses.

[0058] 1. In some embodiments, a housing for one or more moisture-sensitive components, the housing comprising: a first housing member having a first edge that includes a first plurality of edge features; and a second housing member having a second edge that includes a second plurality of edge features configured to interlock with the first plurality of edge features, wherein when the first plurality of edge features interlock with the second plurality of edge features, a first protruding feature among the first plurality of edge features overlaps a gap between a second protruding feature and a third protruding feature among the second plurality of edge features, and the first protruding feature includes a serrated cross-section.

[0059] 2. The housing according to clause 1, wherein the first housing member comprises a hydrophobic material.

[0060] 3. The housing according to clause 1 or 2, wherein the second housing member comprises the hydrophobic material.

[0061] 4. The housing according to any one of clauses 1 to 3, wherein the housing comprises a yoke of a lighting device.

[0062] 5. The housing according to any one of clauses 1 to 4, wherein when the first plurality of edge features interlock with the second plurality of edge features, the first protruding feature among the first plurality of edge features is inserted into a recessed feature among the second plurality of edge features.

[0063] 6. The housing according to any one of clauses 1 to 5, wherein the second protruding feature includes a serration, and the third protruding feature includes the serration.

[0064] 7. The housing according to any one of clauses 1 to 6, wherein the housing is a waterproof gasketless housing.

[0065] 8. The housing according to any one of clauses 1 to 7, wherein when the first plurality of edge features interlock with the second plurality of edge features, the housing includes a spire seam region between the first housing member and the second housing member.

[0066] 9. The housing according to any one of clauses 1 to 8, wherein the first protruding feature includes a first protruding element, a second protruding element parallel to the first protruding element, and a central portion connecting the first protruding element to the second protruding element.

[0067] 10. The housing according to any one of clauses 1 to 9, wherein the central portion forms one of the following: a ninety-degree angle with each of the first protruding element and the second protruding element, an obtuse angle with each of the first protruding element and the second protruding element, or a curved transition with each of the first protruding element and the second protruding element.

[0068] 11. In some embodiments, a device includes one or more moisture-sensitive components and a housing for the one or more moisture-sensitive components, the housing including: a first housing member having a first edge that includes a first plurality of edge features; and a second housing member having a second edge that includes a second plurality of edge features configured to interlock with the first plurality of edge features, wherein when the first plurality of edge features interlock with the second plurality of edge features, a gap between a first protruding feature of the first plurality of edge features and a second protruding feature and a third protruding feature of the second plurality of edge features overlaps, and the first protruding feature includes a serrated cross-section.

[0069] 12. The device according to clause 11, wherein the first housing member includes a hydrophobic material.

[0070] 13. The device according to clause 11 or 12, wherein the second housing member includes the hydrophobic material.

[0071] 14. The device according to any one of clauses 11 to 13, wherein the housing includes a yoke of a lighting device.

[0072] 15. The device according to any one of clauses 11 to 14, wherein when the first plurality of edge features interlock with the second plurality of edge features, the first protruding feature of the first plurality of edge features is inserted into a recessed feature of the second plurality of edge features.

[0073] 16. The device according to any one of clauses 11 to 15, wherein the second protruding feature includes a serration, and the third protruding feature includes the serration.

[0074] 17. The device according to any one of clauses 11 to 16, wherein the housing is a waterproof gasketless housing.

[0075] 18. The device according to any one of clauses 11 to 17, wherein when the first plurality of edge features interlock with the second plurality of edge features, the housing includes a spire seam region between the first housing member and the second housing member.

[0076] 19. The device according to any one of clauses 11 to 18, wherein the first prominent feature includes a first prominent element, a second prominent element parallel to the first prominent element, and a central portion connecting the first prominent element to the second prominent element.

[0077] 20. The device according to any one of clauses 11 to 19, wherein the central portion forms one of the following: a ninety-degree angle with each of the first prominent element and the second prominent element, an obtuse angle with each of the first prominent element and the second prominent element, or a curved transition with each of the first prominent element and the second prominent element.

[0078] Any and all combinations of any claim elements described in any claim and / or any elements described in this application in any way fall within the intended scope of the invention and protection.

[0079] Descriptions of various embodiments have been presented for illustrative purposes, but are not intended to be exhaustive or limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments.

[0080] Aspects of this embodiment may be embodied as a system, method, or computer program product. Accordingly, aspects of the present disclosure may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, microcode, etc.), or an embodiment combining software and hardware aspects, which embodiments are generally referred to herein as "modules", "systems", or "computers". Additionally, any hardware and / or software techniques, processes, functions, components, engines, modules, or systems described in this disclosure may be implemented as a circuit or a collection of circuits. Further, aspects of the present disclosure may take the form of a computer program product embodied in one or more computer-readable media having computer-readable program code embodied thereon.

[0081] Any combination of one or more computer-readable media may be utilized. A computer-readable medium may be a computer-readable signal medium or a computer-readable storage medium. A computer-readable storage medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer-readable storage medium would include the following media: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer-readable storage medium may be any tangible medium that can contain or store a program for use by or in connection with an instruction execution system, apparatus, or device.

[0082] Aspects of the present disclosure are described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the present disclosure. It should be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, implement the functions / acts specified in one or more blocks of the flowchart and / or block diagram. Such a processor may be, but is not limited to, a general purpose processor, a special purpose processor, an application specific processor, or a field programmable gate array.

[0083] The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which includes one or more executable instructions for implementing the specified one or more logical functions. It should also be noted that, in some alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It should also be noted that each block of the block diagrams and / or flowchart illustrations, and combinations of blocks in the block diagrams and / or flowchart illustrations, can be implemented by a system based on dedicated hardware for performing the specified functions or operations, or by a combination of dedicated hardware and computer instructions.

[0084] Although the foregoing is directed to embodiments of the present disclosure, other and additional embodiments of the present disclosure may be devised without departing from its basic scope, which is determined by the claims that follow.

Claims

1. A housing for one or more moisture sensitive components, the housing comprising: a first housing member having a first edge, the first edge comprising a first plurality of edge features; as well as a second housing member having a second edge, the second edge comprising a second plurality of edge features, the second plurality of edge features being configured to interlock with the first plurality of edge features, Wherein when the first plurality of edge features are interlocked with the second plurality of edge features, a first protruding feature of the first plurality of edge features overlaps a gap between a second protruding feature of the second plurality of edge features and a third protruding feature of the second plurality of edge features, and the first protruding feature comprises a sawtooth-shaped cross-section.

2. The housing of claim 1, wherein the first housing member comprises a hydrophobic material.

3. The housing of claim 2, wherein the second housing member comprises the hydrophobic material. The housing of claim 1 , wherein the housing comprises a yoke for a lighting device. 5 . The housing of claim 1 , wherein the first protruding feature of the first plurality of edge features inserts into a recessed feature of the second plurality of edge features when the first plurality of edge features interlock with the second plurality of edge features.

6. The housing of claim 1, wherein the second protruding feature comprises a sawtooth shape, and the third protruding feature comprises the sawtooth shape.

7. The housing of claim 1, wherein the housing is a waterproof gasketless housing.

8. The housing of claim 1, wherein the housing comprises a peaked seam area between the first housing piece and the second housing piece when the first plurality of edge features interlock with the second plurality of edge features.

9. The housing of claim 1 , wherein the first protruding feature comprises: A first protruding element, a second protruding element parallel to the first protruding element, and a central portion connecting the first protruding element to the second protruding element.

10. The housing of claim 9, wherein the central portion forms one of: a ninety degree angle with each of the first protruding element and the second protruding element, an obtuse angle with each of the first protruding element and the second protruding element, or a curved transition with each of the first protruding element and the second protruding element.

11. An apparatus comprising: One or more moisture-sensitive components; as well as A housing for the one or more moisture sensitive components, the housing comprising: a first housing member having a first edge, the first edge comprising a first plurality of edge features; as well as a second housing member having a second edge, the second edge comprising a second plurality of edge features, the second plurality of edge features being configured to interlock with the first plurality of edge features, Wherein when the first plurality of edge features are interlocked with the second plurality of edge features, a first protruding feature of the first plurality of edge features overlaps a gap between a second protruding feature of the second plurality of edge features and a third protruding feature of the second plurality of edge features, and the first protruding feature comprises a sawtooth-shaped cross-section.

12. The device of claim 11, wherein the first housing member comprises a hydrophobic material.

13. The device of claim 12, wherein the second housing member comprises the hydrophobic material.

14. The apparatus of claim 11, wherein the housing comprises a yoke for a lighting device.

15. The apparatus of claim 11, wherein the first protruding feature of the first plurality of edge features inserts into a recessed feature of the second plurality of edge features when the first plurality of edge features interlock with the second plurality of edge features.

16. The device of claim 11, wherein the second protruding feature comprises a sawtooth shape, and the third protruding feature comprises the sawtooth shape.

17. The device of claim 11, wherein the housing is a waterproof gasketless housing.

18. The apparatus of claim 11, wherein the housing comprises a peaked seam region between the first housing piece and the second housing piece when the first plurality of edge features interlock with the second plurality of edge features.

19. The device of claim 11, wherein the first protruding feature comprises: A first protruding element, a second protruding element parallel to the first protruding element, and a central portion connecting the first protruding element to the second protruding element.

20. The device of claim 19, wherein the central portion forms one of: a ninety degree angle with each of the first protruding element and the second protruding element, an obtuse angle with each of the first protruding element and the second protruding element, or a curved transition with each of the first protruding element and the second protruding element.

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