Cladded part

Abstract

A clad part is provided. An enclosure sidewall of a portable electronic device includes an elongated cladding material including: titanium defining an outer surface of the portable electronic device; aluminum fixed to the titanium and defining an inner surface of the portable electronic device; a recessed feature defined by titanium and aluminum; and a non-metallic portion coupled to titanium and aluminum at the recessed feature.

Description

[0001] This patent application is a divisional application of the patent application for invention with the application number 202280064484.9, the application date of September 20, 2022, and the invention title of "Clad Parts".

[0002] Cross - Reference to Related Applications

[0003] This application claims the benefit of U.S. Patent Application No. 17 / 930,031, filed on September 6, 2022, and entitled "CLAD PARTS", and U.S. Provisional Patent Application No. 63 / 261,588, filed on September 24, 2021, and entitled "METHOD FOR ELIMINATING GALVANIC CELL CHARACTERISTICS FOR CLAD PARTS", the disclosures of which are incorporated herein by reference in their entirety. TECHNICAL FIELD

[0004] The described embodiments generally relate to materials for enclosures, structures, and / or electronic devices. More specifically, the present embodiments relate to eliminating or preventing galvanic corrosion of metals in clad parts. BACKGROUND ART

[0005] Technologies related to the use of different materials have become increasingly widespread across various industries and applications, including the portable computing industry and the electronic device industry. For example, the enclosure for an electronic device may include a metal clad material that has a lightweight internal metal within a more durable external metal. Since the weight of the device is important to consumers, it is desirable for the clad material to be a lightweight material with a thin external shell of a durable material.

[0006] However, one difficulty with using different metals is caused by galvanic corrosion. The phenomenon of galvanic corrosion is induced by the potential difference of these different metal materials when different metal materials are brought into contact with an electrolyte (e.g., water). In such a situation, a corrosion current is generated due to the potential difference of the different metal materials. When galvanic corrosion occurs, the strength of the contact points between different metal materials is weakened or the components of the clad material are corroded, resulting in unexpected damage.

[0007] Therefore, one way to prevent galvanic corrosion is to ensure that only the more durable, more corrosion-resistant, and more chemically resistant external metal is exposed to the electrolyte and the internal metal is protected. Unfortunately, this has the effect of moving the material transition between the external metal and the internal metal further away from the exterior of the device, at least where there are openings in the outer surface of the enclosure, resulting in a heavier product. SUMMARY OF THE INVENTION

[0008] According to some embodiments, the outer shell may include a cladding material. The cladding material may include an inner metal disposed within an outer metal. In some examples, the first metal is different from the second metal. The outer shell may also include a cladding interface and a melt interface. The melt interface may include a hardened flux layer disposed on a portion of the inner metal.

[0009] In other words, the outer metal may include a metal that is less susceptible to corrosion than the inner metal. The outer metal may include stainless steel or titanium, and the inner metal may include aluminum. In some embodiments, the outer metal may include a uniform grain structure at the cladding interface and a non-uniform grain structure at the melt interface. In some examples, the hardened flux layer may include a thickness from about 100 μm to about 800 μm. The hardened flux may include an adhesive tensile strength greater than about 300 MPa. In some examples, the outer metal proximate the cladding interface may include a different hardness than the outer metal proximate the melt interface. In some embodiments, the melt interface may include a tangential grain flow relative to the cladding interface.

[0010] According to some embodiments, a method of forming a protective interface in an outer shell may include disposing a cladding interface between an outer metal and an inner metal. The outer metal may include an outer surface and an inner surface. The method may include machining the inner metal to remove a portion of the inner metal that contacts the outer metal, and forming a hole in the outer metal. In some examples, forming a hole in the outer metal may include forming a protective interface at an inner surface of the hole adjacent to the inner metal.

[0011] In some examples, forming the hole may include drilling through the outer metal from the outer surface with a hot drill. In other examples, forming the hole may include drilling through the outer metal from the inner surface with a hot drill. In some examples, the method of forming a protective interface in the outer shell may further include forming a counterbore in the cladding shell. In some examples, forming the hole may include extruding the outer metal through the removed portion of the inner metal. In other examples, forming the hole may include machining a portion of the outer metal from the inner surface, and press-fitting a slug into an opening formed by machining a portion of the outer metal, and machining the hole through the slug.

[0012] In some embodiments, the interface disposed between the slug and the outer metal may include a sealant. In some embodiments, the bond between the slug and the outer metal may include at least one of friction welding or laser welding. In some embodiments, the slug may include a flange configured to secure the slug.

[0013] According to some embodiments, a system configured to prevent galvanic corrosion of a housing may include a cladding structure having an external metal and an internal metal joined at an interface. In some examples, the internal metal defines an aperture at the interface. An insert may be disposed between the external metal and the internal metal within the aperture, and an adhesive may be configured to bond the insert within the aperture. In some examples, a hole may be formed through the cladding structure and the insert. In some embodiments, the insert may include a metal or plastic. In some examples, the insert may include lobes extending from an external surface of the insert. The lobes may be configured to center the insert within the hole. In some embodiments, the hole may include a non-circular shape. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, in which like reference numerals refer to like structural elements, and in which:

[0015] Figure 1 A perspective view of an electronic device having a housing is illustrated.

[0016] Figure 2A A cross-sectional view of a portion of the electronic device is illustrated.

[0017] Figures 2B to 2C A cross-sectional view of a portion of the electronic device is illustrated, showing an internal metal vulnerable to galvanic corrosion.

[0018] Figure 3A A cross-sectional view of a cladding material having an internal metal disposed within an external metal is illustrated.

[0019] Figure 3B Illustrates Figure 3A the cladding material in which the internal metal is machined to remove a portion of the internal metal that contacts the external metal.

[0020] Figure 3C Illustrates Figure 3A the cladding material in which the internal metal is machined to remove a portion of the internal metal that contacts the external metal, and the external metal is machined to include screw threads.

[0021] Figure 4A A cross-sectional view of a cladding material having a hole formed in the external metal is illustrated, in which a thermal drill drills through the external metal from the outer surface.

[0022] Figure 4B Illustrates Figure 4A the cladding material in which the external metal and the internal metal are partially machined.

[0023] Figure 5AA cross-sectional view of a cladding material having holes formed in an outer metal is illustrated, where a thermal drill drills through the outer metal from the inner surface.

[0024] Figure 5B Illustrates Figure 5A of a cladding material, where the outer metal and the inner metal are partially machined.

[0025] Figure 5C Illustrates Figure 5A of a cladding material, where the outer metal and the inner metal are partially machined, and the outer metal is machined to include screw threads.

[0026] Figure 6A A cross-sectional view of a cladding material is illustrated, where holes are formed in the outer metal by extruding the outer metal through a removed portion of the inner metal.

[0027] Figure 6B Illustrates Figure 6A of a cladding material, where the outer metal and the inner metal are partially machined.

[0028] Figure 7A A cross-sectional view of a cladding material is illustrated, where holes are formed in the outer metal by machining a portion of the outer metal and removing a portion of the inner metal.

[0029] Figure 7B Illustrates Figure 7A of a cladding material, where inserts are press-fitted into a machined portion of the outer metal.

[0030] Figure 7C Illustrates Figures 7A to 7B of a cladding material, where the outer metal and the inner metal are partially machined, and holes are machined through the inserts.

[0031] Figure 8 A cross-sectional view of a cladding material having holes and a protective interface is illustrated, where a pressed button is disposed within the holes, and the protective interface is formed between the inner metal and the outer metal at the periphery of the holes.

[0032] Figure 9 Illustrates a method of forming a protective interface in a housing.

[0033] Figure 10A A perspective view of a housing is illustrated, where a portion of the housing is removed and an insert is placed into the removed portion.

[0034] Figure 10B Illustrates Figure 10A of a housing, where the insert is disposed between the outer metal and the inner metal within a removed portion of the inner metal.

[0035] Figure 10C illustrates Figure 10A a housing in which holes are machined through a cladding structure and an insert.

[0036] Figure 11 illustrates a perspective view of the housing in which a portion of the housing is removed and the insert is placed in the removed portion. DETAILED DESCRIPTION

[0037] Reference will now be made specifically to representative embodiments shown in the accompanying drawings. It should be understood that the following description is not intended to limit the embodiments to one preferred embodiment. On the contrary, it is intended to cover alternative forms, modifications, and equivalents that may be included within the spirit and scope of the described embodiments as defined by the appended claims.

[0038] The following disclosure relates to a system for protecting a device against galvanic corrosion. In some embodiments, an electronic device may include a housing made of a cladding material. In other words, the housing may include an outer metal and an inner metal different from the outer metal. When an electronic device having such a configuration is exposed to seawater, rain, sweat, or any other water that enters the device body from the outside, the water may penetrate between the openings on the outside of the device and cause galvanic corrosion of the inner metal.

[0039] In certain embodiments, the outer metal may include a metal that is more corrosion-resistant than the inner metal. In other words, the outer metal may include a metal that is less susceptible to corrosion than the inner metal. Thus, one way to prevent galvanic corrosion is to ensure that only the outer metal is exposed to an electrolyte (e.g., water), and the inner metal is kept inside the device in a water-impermeable configuration. Generally, the outer metal may be heavier than the inner metal. Therefore, moving the interface between the outer metal and the inner metal further away from the outer surface of the device may result in a heavier device, and weight can be an important aspect of a consumer device. In some embodiments, weight reduction benefits may be achieved by forming a new interface between the outer metal and the inner metal in the vulnerable areas such that the thin outer metal shell and the inner metal are protected from the electrolyte in the openings and the vulnerable areas.

[0040] Reference is made below to Figures 1 to 11Let's discuss these embodiments and other embodiments. However, those skilled in the art will readily understand that the detailed descriptions given herein with respect to these figures are for illustrative purposes only and should not be construed as restrictive. Additionally, as used herein, a system, method, article of manufacture, component, feature, or sub-feature that includes at least one of a first option, a second option, or a third option should be understood to refer to a system, method, article of manufacture, component, feature, or sub-feature that may include one (e.g., only one first option, only one second option, only one third option) of each of the listed options, multiple of a single listed option (e.g., two or more first options), two options simultaneously (e.g., one first option and one second option), or a combination thereof (e.g., two first options and one second option).

[0041] Figure 1 A perspective view of an electronic device having a housing that may include the systems and techniques described herein, in accordance with some embodiments, is illustrated. Figure 1 The smartphone 100 is illustrated. However, these systems and techniques are not limited to a particular device and may be included in any suitable device (e.g., a phone, a tablet computer, a smartwatch, a portable computer, etc.). According to some embodiments, the housing 102 may include a cladding material. As discussed above, in some embodiments, the housing 102 may include a number of openings and / or interfaces that are susceptible to electrolytes (e.g., water, sweat) to penetrate the exterior of the housing and cause corrosion of internal metals and / or internal components. For example, as Figure 1 shown, the housing 102 may include at least one button 104, a switch 106, a speaker 108, a camera interface 110, etc.

[0042] In some embodiments, the housing 102 may include two metals that form the cladding material. The exterior metal may include a metal that is less susceptible to corrosion than the interior metal. The exterior metal may include a generally corrosion-resistant metal (e.g., high-strength stainless steel, titanium, etc.) and the interior metal may include a more electrochemically active metal that is lighter in weight than the exterior metal (e.g., aluminum, aluminum alloy, magnesium, magnesium alloy, beryllium, beryllium alloy, etc.). The exterior metal and the interior metal may include galvanically different metals. Galvanic corrosion refers to the corrosion damage that occurs when two different metals are in electrical contact in the presence of an electrolyte, where the noble metal is more protected and the more active metal is more likely to be corroded. The designer of the housing 102 attempts to balance the durability of the device with the weight of the device. Consumers may prefer a lighter device, so the designer may attempt to maximize the use of the lighter interior metal (e.g., the more active metal) in the housing.

[0043] Figure 2AA cross-sectional view of a portion of an electronic device 200 according to one embodiment is illustrated. The electronic device 200 may include a housing 202 that includes a cladding material having an internal metal 204 disposed within an external metal 206. The external metal 206 may be different from the internal metal 204. In some examples, the external metal 206 may include an alloy different from the internal metal 204. In other examples, the external metal 206 may include a processing technique (e.g., anodization, PVD), a coating technique (e.g., chemical conversion, painting, powder coating), or an electroplating technique (e.g., chrome plating, gold plating, or silver plating) that does not have to be applied to the internal metal 204. In some embodiments, the external metal 206 includes a metal that is less susceptible to corrosion than the internal metal. In other words, the internal metal 204 may be subject to galvanic corrosion, causing the internal metal 204 to crack, corrode, or lose strength.

[0044] The internal metal 204 and the external metal 206 may include the cladding material. The internal metal 204 and the external metal 206 include an interface where the internal metal 204 and the external metal 206 contact. The interface may include a cladding interface 208. The cladding interface 208 may include a uniform grain structure and a uniform contact surface of the internal metal 204 and the external metal 206. As Figure 2A shown, the housing 202 may also include components that result in an opening leading to the interior of the electronic device 200. For example, a display 210 or a backing 212 of the electronic device 200 (e.g., a screen) may be configured to contact the external metal 206 and / or the internal metal 204. The display 210 and / or the backing 212 do not require any movement between the housing 202 and the display 210 and / or the backing, and thus may be sealed with an adhesive 214 at the interface between the housing 202 and the display 210 and at the interface between the housing 202 and the backing 212. The adhesive 212 may be configured to seal the electronic device 200 and prevent any electrolyte from entering the interface between the housing 202 and the display 210, and thus prevent any corrosion.

[0045] The housing 202 may also include a button 216. In some examples, the button 216 may be pressed and / or released. Figure 2A The button 216 is shown as being pressed. To maintain the area inside the housing 202, in some examples, an O-ring 218 may be included. The O-ring 218 may be configured to seal the housing 202 and prevent the internal metal 204 from being exposed to the electrolyte and prevent galvanic corrosion of the internal metal 204. However, as Figure 2A shown, in some embodiments, when the button 216 is pressed, the O-ring 218 is disposed inside the cladding interface 208, and a portion of the internal metal 204 may be exposed to the electrolyte. In some examples, when the button 216 is pressed, the area inside the O-ring 218 remains watertight, but the exposure of the internal metal 204 may cause galvanic corrosion of the housing 202.

[0046] Figures 2B to 2C A cross-sectional view illustrating a portion of an electronic device 200, showing an internal metal 204 that is susceptible to galvanic corrosion. Figure 2C is Figure 2B An enlarged portion of, to better illustrate the potential effect of galvanic corrosion on the internal metal when the internal metal 204 is exposed to an electrolyte. Galvanic corrosion, also known as bimetallic corrosion, is an electrocouple process whereby one metal corrodes preferentially to another metal in contact through an electrolyte. Galvanic corrosion occurs when two different metals are placed in an electrically conductive solution and are electrically connected. One metal (the cathode, such as the external metal 206) can be protected while the other metal (the anode, such as the internal metal 204) undergoes corrosion. The rate of erosion on the anode can be accelerated compared to the rate of erosion when the metal is decoupled from the external metal 206.

[0047] Figure 3A A cross-sectional view illustrating a cladding material 300 having an internal metal 302 disposed within an external metal 304, according to one embodiment. As briefly described above, an advantage of the cladding material is that the material combines the excellent properties of each metal. For example, by including the cladding material within an enclosure, strength, corrosion resistance, lightweighting, cost, thermal conductivity, and electrical conductivity can be improved. Thus, the materials produced by cladding are superior to individual metals alone. In some examples, the cladding material 300 can be manufactured by roll bonding the internal metal 302 to the external metal 304 to produce a metallurgically bonded cladding interface 306. Many metals can be combined with this technique to provide customized metals with specific desired properties. In some embodiments, the external metal 304 can include stainless steel or titanium, and the internal metal 302 can include aluminum, aluminum alloy, magnesium, magnesium alloy, beryllium, beryllium alloy, or any other suitable metal. In some embodiments, the external metal can include a uniform grain structure at the cladding interface 306.

[0048] In some embodiments, roll bonding can be achieved by processing the internal metal 302 and the external metal 304 through a conventional sheet hot rolling mill that reduces the thickness and metallurgically bonds the internal metal 302 to the external metal 304. The cladding material 300 can be formed into different shapes, which allows designers the freedom to produce a variety of devices (such as enclosures for electronic devices). The cladding material 300 can be cut and formed by most shop operations, including shearing, plasma cutting, stretching, bending, thermoforming, machining, drilling, and stamping.

[0049] Figure 3B Illustrates according to one embodiment Figure 3AThe cladding material 300, wherein the internal metal 302 is machined to remove the portion of the internal metal 302 that contacts the external metal 304. In other words, the internal metal 302 can be machined to produce a machined surface. The manufacturing / machining process produces a surface characterized by shape (topography), metallurgy, and mechanical properties. In some examples, the surface aspects can indicate that the machined surface includes complex parts and a system of relevant features that affect the surface functional performance. Machining is a manufacturing term that encompasses a wide range of techniques and skills. The machining can be roughly defined as the process of using a machine tool to remove material from the cladding material 300 to shape it into the desired design. Figure 3B is a machined surface of the internal metal 302 that has been removed through the entire thickness of the internal metal 302. In other words, the internal metal 302 is machined to the cladding interface 306. Techniques and methods for forming a system to prevent galvanic corrosion can include the machined cladding material 300 as the initial material for forming an additional interface that can protect the internal metal 302.

[0050] Figure 3C Illustrates according to one embodiment Figure 3A The cladding material 300, wherein the internal metal 302 is machined to remove the portion of the internal metal 302 that contacts the external metal 304 and is further machined to remove a portion of the external metal 304. The internal metal 302 can be pre-drilled, through the cladding interface 306 and into the external metal 304. In some examples, the internal metal 302 can be further machined to expand the removed portion of the internal metal 302 to form a countersink 308. In some examples, the countersink 308 can include a countersink depth 308a that extends through the cladding interface 306 and into the external metal 304.

[0051] The countersink depth 308a can be machined such that the threads 310 are formed only in the external metal 304. In some examples, the external metal 304 can include a stronger and more durable metal (e.g., stainless steel), and the internal metal 302 can include a lighter but softer metal (e.g., aluminum) that is more susceptible to screw thread deformation, thread failure, and / or thread misalignment than the external metal 304. Since the countersink depth 308a extends further than the internal metal 302, the likelihood of thread deformation is smaller.

[0052] In some examples, the countersink 308 may include a countersink diameter 308b that limits the insertion angle of the screw when the screw contacts the screw threads 310. In some examples, the countersink diameter 308b is narrow relative to the diameter of the screw to reduce the insertion angle and minimize the likelihood of thread cross-threading. For example, the countersink depth 308a and the countersink diameter 308b may be configured to limit the insertion angle of the screw to a maximum variation of about 3° relative to the centerline of the countersink 308. In other examples, the insertion angle of the screw may be further limited to less than 3°. Because the countersink diameter 308b is formed to reduce the insertion angle, the likelihood of thread cross-threading is also significantly reduced compared to a threaded hole opening without a countersink.

[0053] Figure 4A A cross-sectional view of a cladding material 400 having a hole formed in an outer metal according to one embodiment is illustrated, where a thermal drill drills through the outer metal from the outer surface. The cladding material 400 may include an inner metal 402 and an outer metal 404. In some embodiments, the inner metal 402 may be disposed within the outer metal 404. The outer metal 404 may be different from the inner metal 402 (e.g., different electrode potentials). The cladding material 400 may include a cladding interface 406 where the inner metal 402 and the outer metal 404 contact. In some embodiments, the cladding material 400 may further include a melt interface 408. In some examples, the melt interface 408 may include a hardened flux layer disposed on a portion of the inner metal 402. In some examples, the hardened flux refers to a metal that is heated to a different state (e.g., liquid state) and then allowed to cool and harden. In other words, the hardened flux includes a metal layer that is heated above its melting point and then cooled below that melting point. For example, the melt interface 408 may include a hardened flux formed by a molten portion of the outer metal 404 that flows on the surface of the inner metal 402. In some examples, the hardened flux may be heated by friction and / or extrusion and then cooled by withdrawing the friction device or ending the extrusion process.

[0054] In some examples, the outer metal 404 may include a corrosion-resistant metal (e.g., stainless steel), and the inner metal 402 may include a metal that is more susceptible to corrosion than the outer metal 404 (e.g., aluminum). The cladding interface 406 and the melt interface 408 may prevent the inner metal 402 from being exposed to an electrolyte and prevent galvanic corrosion of the inner metal 402. In some embodiments, the melt interface 408 may include a high adhesion strength between the outer metal 404 and the inner metal 402.

[0055] In some examples, the cladding material 400 may include holes 410. The holes 410 may penetrate both the outer metal 404 and the inner metal 402. In some embodiments, the holes 410 may be formed by a hot drill extending from the outer surface 412 of the cladding material 400 through the outer metal 404. In some examples, the hot drill uses friction to create the holes 410. The combined rotational and downward forces of an exemplary hot drilling bit may generate frictional heat. In one example, the outer metal 404 is transformed into a “superplastic” state, allowing the tool to displace the outer metal 404 material and form a melt interface 408. The length of the melt interface may include approximately three to four times the original thickness of the outer metal 404. Hot drilling can be used on most ferrous and non-ferrous metals with material thicknesses up to 12 mm, including plain steel, stainless steel, copper, brass, and aluminum. Generally, all ductile materials can be hot drilled. In some embodiments, the outer metal 404 may include a thickness of about 100 μm to about 800 μm at the melt interface 408. In some examples, the outer metal 404 at the melt interface 408 may include a thickness greater than about 100 μm. In some embodiments, the thickness of the outer metal 404 at the melt interface 408 may be about 100 μm or greater, about 200 μm or greater, about 300 μm or greater, about 400 μm or greater, about 500 μm or greater, about 600 μm or greater, about 700 μm or greater, or in the range of about 100 μm to about 200 μm, about 200 μm to about 300 μm, about 300 μm to about 400 μm, about 400 μm to about 500 μm, about 500 μm to about 600 μm, about 600 μm to about 700, or about 700 μm to about 800 μm. After the holes 410 are included in the cladding material 400, the cladding material may be further machined to form the cladding material as required by the exemplary design.

[0056] Figure 4B Illustrated Figure 4AThe cladding material 400, in which the outer metal 404 and the inner metal 402 are partially machined. In some embodiments, the outer metal 404 may include a uniform grain structure 414 at the cladding interface 406. Generally, the internal structure of a metal (e.g., the outer metal 404) is composed of individual crystalline regions called grains. The structure, size, and orientation of these grains depend on the material composition (alloy) and the way the material is manufactured. In some embodiments, the outer metal 404 may include stainless steel. The "superplastic" state formed in the outer metal 404 at the melt interface 408 may cause the grains of the outer metal 404 to be non-uniform. Thus, the outer metal 404 may include a non-uniform grain structure 416 at the melt interface 408. In some embodiments, the non-uniform grain structure 416 causes the outer metal 404 at the melt interface 408 to soften after the outer metal 404 cools from the "superplastic" state. In other words, the outer metal 404 near the cladding interface 406 may have a different hardness from the outer metal 404 near the melt interface 408. In some embodiments, the hardness of the outer metal 404 near the cladding interface 406 may be greater than the hardness of the outer metal 404 near the melt interface. In other embodiments, the hardness of the outer metal 404 near the cladding interface 406 may be less than the hardness of the outer metal 404 near the melt interface

[0057] In some embodiments, the melt interface 408 may include an angle between about 45° and about 90° relative to the cladding interface 406. When the outer metal 404 is in a superplastic state, the angle between the melt interface 408 and the cladding interface 406 may change due to the formation of the melt interface 408. In some embodiments, the melt interface 408 may include a tangential grain flow relative to the cladding interface 406. In some embodiments, the melt interface 408 may include an adhesion tensile strength greater than about 300 MPa. Different techniques for forming the melt interface between the outer metal and the inner metal may result in different characteristics of the angle and the adhesion strength. In some examples, the melt interface 408 may be threaded to include screw threads or other fastener fixing features

[0058] Figure 5A A cross-sectional view of a cladding material 500 having holes formed in the outer metal according to one embodiment is illustrated, where a hot drill drills through the outer metal from the inner surface. The cladding material 500 may include an inner metal 502 and an outer metal 504. Similar to Figures 4A to 4BIn the illustrated embodiment, the cladding material 500 may include a cladding interface 506 where an internal metal 502 contacts an external metal 504. In some embodiments, the cladding material 500 may further include a melt interface 508. In some examples, the melt interface 508 may include a hardened flux layer disposed on a portion of the internal metal 502. In some examples, thermal drilling uses friction to create a blind hole 510. The blind hole 510 may be defined as a hole or cavity drilled from an inner surface 512 into the external metal 504, where the hole or cavity does not penetrate the outer surface 514 of the external metal 504. In some examples, as Figure 5A illustrated, a thermal drill extending from the outer surface 514 of the cladding material 500 to but not completely through the external metal 504 may form a hole 510. In some examples, thermal drilling uses friction to create the hole 510. The external metal 504 is transformed into a "superplastic" state, allowing the tool to displace the external metal 504 material and form a melt interface 508.

[0059] Figure 5B is illustrated Figure 5A of the cladding material 500, where the external metal 504 and the internal metal 502 are partially machined. Similar to the cladding material 400 illustrated above Figures 4A to 4B The "superplastic" state formed in the external metal 504 at the melt interface 508 may result in non-uniform grains of the external metal 504. Thus, the external metal 504 may include a non-uniform grain structure 516 at the melt interface 508. In some embodiments, the melt interface 508 may include a tangential grain flow relative to the cladding interface 506. In some embodiments, the non-uniform grain structure 516 causes the external metal 504 at the melt interface 508 to soften after the external metal 504 cools from the "superplastic" state. In some examples, the remaining portion of the external metal 504 located at the blind hole 510 may be machined away at a later stage of the design process. Thus, the melt interface 508 may include an angle that is closer to 90° or at least between about 45° and 90° relative to the cladding interface 506.

[0060] Figure 5C is illustrated Figure 5AA clad material 500 is provided in which the outer metal 504 and the inner metal 502 are partially machined, and the outer metal 504 is further machined to include screw threads. In some examples, the clad material 500 also includes a melt interface 508, which may include a hardened flux layer disposed on a portion of the inner metal 502. A hot drill may be used to create a blind hole 510. The hot drill may extend from an outer surface 514 of the clad material 500 to, but not completely through, the outer metal 504, and may form the hole 510. In other words, the hole 510 may extend from the inner surface 512 through the clad interface 506, but not through the outer metal 504. In some examples, the hole 510 may be threaded to form a screw thread 518. The melt interface 508 is formed by the stronger and more durable outer metal 504 to minimize the possibility of screw thread deformation, thread failure, and / or thread cross-threading compared to the inner metal 302. Because the threads are included in the melt interface 508 of the outer metal 504, the possibility of thread deformation is less. In some examples, the melt interface 508 may include other fastener securing features instead of screw threads. Figures 6A to 6B In some examples described in detail, the hole 510 may extend completely through the cladding material 500, and the screw threads may be formed throughout the hole, thereby allowing the fastener to be inserted from either side of the hole. Figures 6A to 6B Additional details of the through-holes are provided.

[0061] Figure 6A A cross-sectional view of a clad material 600 is illustrated in accordance with one embodiment, wherein a hole is formed in the outer metal by extruding the outer metal through a removed portion of the inner metal. The clad material 600 may include an inner metal 602 and an outer metal 604. Similar to Figures 4A to 4B and Figures 5A to 5B In the illustrated embodiment, the cladding material 600 may include a cladding interface 606 where the inner metal 602 and the outer metal 604 contact. In some embodiments, the cladding material 600 may also include a protective interface 608. In one example, the protective interface 608 is formed by an extrusion process. Metal extrusion is a metal forming manufacturing process in which a blank inside a closed cavity is forced to flow through a die having a desired cross-section. Metal extrusion processes are widely used today due to fast and high productivity and low cost. In addition, both hot metal extrusion processes and cold metal extrusion processes can be used. The cross-section of the produced outer metal 604 will be uniform over the entire length of the metal extrusion. In some examples, the hole 610 may be formed as a hollow in the extrusion process or may be machined in a later step of the process.

[0062] Figure 6B Illustrated Figure 6A The cladding material 600, wherein the outer metal 604 and the inner metal 602 are partially machined.Figure 6B As shown, in some embodiments, the extruded protective interface 608 may include a more uniform grain structure 612 than other methods. In some examples, the extruded protective interface 608 may be threaded to include screw threads or other fastener securing features. In some examples, the adhesive tensile strength of the extruded protective interface 608 may be less than the melt interface of other methods (e.g., Figures 4A to 4B the melt interface of ). In some embodiments, the extruded protective interface may be the gap between the internal metal 602 and the external metal 604. However, the hole 610 may include a non-circular shape. Other advantages of extrusion for forming the protective interface 608 may include uniformity of production, cost, and speed. Other benefits may be provided by other manufacturing processes.

[0063] Figure 7A Illustrated is a cross-sectional view of a cladding material 700 according to one embodiment, where the hole is formed in the external metal by machining a portion of the external metal and removing a portion of the internal metal. The cladding material 700 may include an internal metal 702 and an external metal 704 similar to the above embodiments. In one example, according to one embodiment, the internal metal 702 may be machined to remove the portion of the internal metal 702 that contacts the external metal 704. A portion of the external metal 704 may also be machined. The cladding material 700 may include a cladding interface 706 where the internal metal 702 and the external metal 704 contact. The cladding material 700 may further include a hole 708 extending through the external metal 704. The hole 708 may include a smaller diameter than the machined portion of the external metal 704. The hole 708 may be machined, cut, or formed using any suitable method.

[0064] Figure 7B Illustrated Figure 7AThe cladding material 700, where the insert 710 is press-fitted into the machined portion of the outer metal 704. In some examples, the insert 710 may include the same metal as the outer metal 704. In some examples, the insert 710 may include any other suitable metal or non-metal (e.g., plastic or ceramic). In some examples, the insert 710 may include a non-circular shape. The insert 710 may include geometric features (e.g., grooves or teeth) around the circumference of the insert 710 to interlock within the inner metal 702 and / or the outer metal 704. In some embodiments, the interface disposed between the insert 710 and the outer metal 704 and / or the inner metal 702 may include a sealant 712. The sealant 712 may include an epoxy resin or a polymer sealant. The sealant 712 may include silicone or any other suitable sealant. In some embodiments, the interface disposed between the insert 710 and the outer metal 704 and / or the inner metal 702 may include a protective interface 714. In some examples, the bond between the insert 710 and the outer metal 704 may include at least one of friction welding or laser welding. Friction welding generates heat through the mechanical friction of relative movement between the insert 710 and the outer material 704 and / or the inner material 702, where a lateral force called "upsetting" is added to plastically displace and fuse the materials. Laser welding is a process for joining metals using a laser beam to form a weld, and can be practiced using previously known methods.

[0065] Figure 7C illustrates Figures 7A to 7B The cladding material 700, where the outer metal 704 and the inner metal 702 are partially machined, and a hole 708 is machined through the insert 710. In some examples, the wall of the hole 708 formed by the insert 710 may be tapped or otherwise machined to form threads, such as screw threads or other fastener fixing features. In some examples, the insert 710 may include a flange 716 configured to fix the insert 710 within the machined portion of the outer metal 704. In some embodiments, a portion of the insert 710 may include the flange 716. As Figure 7C shown, the protective interface 714 may include an angle that is closer to 90° or at least between about 45° and 90° relative to the cladding interface 706. In other words, the interface disposed between the insert 710 and the outer metal 704 and / or the inner metal 702 may include an angle of about 90° relative to the cladding interface 706.

[0066] As briefly described above, the holes within the housing can be made to fit various features (e.g., buttons, switches, etc.) to be included on the housing. Figure 8A cross-sectional view of a housing 800 having a cladding material 801 and a hole is illustrated according to one embodiment, where a pressed button is disposed within the hole, and a protective interface is formed at the periphery of the hole between an inner metal and an outer metal. Similar to the above embodiments, the cladding material 801 may include an inner metal 802 and an outer metal 804. The cladding material 801 may include a cladding interface 806 where the inner metal 802 and the outer metal 804 are in contact. In some embodiments, the cladding material 801 may further include a protective interface 808. The housing 800 may further include a button 810. In some examples, the button 810 may be pressed and / or released. Figure 8 The button 810 of Figure 8 is shown as being pressed. To maintain the area inside the housing 800, in some examples, an O-ring 812 may be included. The O-ring 812 may be configured to seal the housing 800 and prevent the inner metal 804 from being exposed to the electrolyte, and prevent galvanic corrosion of the inner metal 804. As compared with Figure 2A the embodiment shown in Figure 2A , when the button 810 is pressed, the protective interface 808 ensures that the inner metal 802 is not exposed to the electrolyte. The inner metal 802 remains within the watertight portion of the housing 800 and is protected by the outer metal 804 and / or the O-ring 812. Any one of the housings and / or cladding material systems discussed above with reference to Figures 3A to 7C Figures 3A to 7C may be included in the housing, either alone or in combination, to eliminate galvanic corrosion.

[0067] Figure 9 A method 900 of forming a protective interface in a cladding housing according to one embodiment is illustrated. In some embodiments, the method 900 may include forming a raw cladding material, as shown in block 902. The raw cladding material may be formed by roll bonding, press fitting, extrusion, or any other suitable method known in the art. In some embodiments, the raw cladding material may include an inner metal disposed within an outer metal. In some embodiments, the cladding material may be preformed such that the cladding housing includes a cladding interface disposed between the outer metal and the inner metal. The raw cladding material may include a cladding interface disposed between the outer metal and the inner metal; the outer metal may include an outer surface and an inner surface.

[0068] At block 904, the method may include machining the inner metal to remove a portion of the inner metal that contacts the outer metal. The machining may result in a portion of the raw cladding material that includes only the outer metal. At block 904, the method may further include machining the inner metal as required by the design of the interior of the housing.

[0069] The method may also include forming a hole in the outer metal, as shown in block 906. In some embodiments, a protective interface may be formed between the inner metal and the outer metal adjacent to the inner metal. The protective interface may prevent the inner metal from being exposed to the electrolyte and prevent galvanic corrosion of the inner metal. In some embodiments, forming the hole may include drilling through the outer metal from the outer surface using a thermal drill. In some examples, the thermal drill forms the protective interface by heating and displacing a portion of the outer metal. In other examples, forming the hole may include drilling through the outer metal from the inner surface using a thermal drill. Again, the thermal drill forms the protective interface by heating and displacing a portion of the outer metal.

[0070] In some embodiments, forming the hole may include machining the hole into the outer metal to remove a portion of the outer metal. The portion of the outer metal may include a hole having a diameter smaller than the diameter of the hole machined into the inner metal at block 904. In some embodiments, the outer metal may be pushed or punched into the relatively larger hole machined into the inner metal from the outer direction by transitionally displacing the portion of the outer metal into the machined portion of the inner metal, thereby forming the protective interface. In some embodiments, the outer metal may be pulled into the relatively larger hole machined into the inner metal to form the protective interface.

[0071] In some embodiments, forming the hole may include extruding the outer metal through the removed portion of the inner metal. The extruded portion may have the benefit of a uniform thickness at the protective interface. In some embodiments, the extruded portion may also include a uniform grain structure at the protective interface. The uniform grain structure may include a hardness at the protective interface that is comparable to the hardness of the outer metal of the original cladding material.

[0072] In some examples, forming the hole may include a hydrostatic extrusion process. The hydrostatic extrusion may include a punch powered by a mechanical or hydraulic press. The punch is configured to force the metal (e.g., the outer metal) to flow into a certain shape. In some examples, the metal is configured to flow in a direction opposite to the delivered force and around the punch. In some examples, the punching force may be from the inner side of the outer metal, causing the metal to form the protective interface around the punch. In other examples, the punch may be configured to impact the outer metal from the outer side, causing the outer metal to be punched into the hole machined from the inner metal at block 904. In this example, a portion of the outer metal may be sheared into the hole machined from the inner metal due to the impact of the punch. The protective interface may be formed by machining through a portion of the outer metal having a diameter smaller than the punch and / or the hole machined from the inner metal at block 904.

[0073] In some embodiments, forming the hole may include machining a portion of the outer metal from the inner surface and press-fitting the insert into the opening formed by machining a portion of the outer metal. Forming the hole may also include machining a hole through the insert. The hole may be machined through the insert from the inner surface and / or the outer surface. In some examples, the insert may include the same metal as the outer metal. In other examples, the insert may include a different metal or a non-metal (e.g., plastic, ceramic, etc.). In some examples, the interface disposed between the insert and the outer metal may include a sealant to help protect the inner metal and secure the insert. In some examples, the bond between the insert and the outer metal may include at least one of friction welding or laser welding. Other examples may include a flange on at least a portion of the insert configured to secure the insert within the outer metal and / or the inner metal.

[0074] May include a system configured to prevent galvanic corrosion of the housing. Figure 10A Illustrates a perspective view of a housing 1000 according to one embodiment, where a portion of the housing 1000 has been removed and an insert is placed into the removed portion. In some embodiments, the housing 1000 may include a cladding structure 1002 having an outer metal 1004 and an inner metal 1006. Figure 10A The illustrated housing has been machined to include various features and holes configured to provide functionality to an electronic device. In some embodiments, a hole 1008 may be formed into the cladding structure 1002. The hole may include a non-circular shape. In some examples, the hole 1008 includes an opening in the outer metal 1004 of the cladding structure 1002. The hole 1008 may also include an opening through the inner metal 1006 of the cladding structure 1002. The cladding structure 1002 may also include an aperture or recess 1010 machined into the cladding structure 1002. The aperture 1010 may be configured to mate an insert 1012 within the aperture 1010. In some embodiments, the inner metal 1006 defines the aperture 1010 at the interface.

[0075] Figure 10B Illustrates Figure 10Aa housing 1000, wherein an insert 1012 is disposed within a removed portion of an inner metal 1006 between an outer metal 1004 and the inner metal 1006. In other words, the inner metal 1006 defines an orifice at the interface of the cladding structure 1002. In some embodiments, the insert 1012 may be disposed within an orifice (e.g., a recess 1010) of the inner metal 1006 between the outer metal 1004 and the inner metal 1006. In some embodiments, the insert 1012 may comprise a corrosion-resistant metal. In other embodiments, the insert 1012 may comprise a metal, a polymer, or a plastic. The insert may comprise any suitable material that does not cause galvanic corrosion of the cladding structure 1002. In some embodiments, the insert 1012 is held in place with an adhesive that is configured to bond the insert within the removed portion of the cladding structure 1002.

[0076] Figure 10C illustrates Figure 10A a housing 1000, wherein a hole is formed through the cladding structure 1002 and the insert 1012. The inner metal 1006 of the housing 1000 may be protected from electrolytes and galvanic corrosion because the insert ensures that the inner metal 1006 is not exposed to the exterior of the waterproof interior of the housing 1000. The insert 1012 may be disposed between the outer metal 1004 and the inner metal 1006, and the insert 1012 may comprise more than one hole machined through the insert 1012.

[0077] Figure 11 illustrates a perspective view of a housing 1100 according to one embodiment, wherein a portion of the housing 1100 is removed and an insert is placed into the removed portion. In some embodiments, the housing 1100 may comprise a cladding structure 1102 having an outer metal 1104 and an inner metal 1106. The insert 1108 is shown inserted into a hole 1110 of the cladding structure 1102. In some embodiments, the insert 1108 may comprise a protrusion 1112 on an outer surface of the insert 1108. The protrusion 1112 may be included to ensure that the insert 1108 is properly spaced when placed into the hole 1110 such that the insert 1108 can be properly aligned and / or an adhesive can be applied evenly around the insert 1108. In some embodiments, the insert 1108 may comprise extensions or "teeth" structures around the circumference of the insert 1108 that fix the insert within the hole 1110. In some embodiments, an adhesive 1114 may be included to fix the insert 1108 to the hole 1110. In some embodiments, the adhesive 1114 may be an electronic-grade silicone adhesive or sealant, an epoxy resin, or a light-curing adhesive.

[0078] To the extent applicable to the present technology, data collected and used from various sources can be used to improve the delivery of inspirational content or any other content that a user may be interested in. The present disclosure anticipates that, in some instances, such collected data may include personal information data that uniquely identifies or can be used to contact or locate a specific person. Such personal information data may include demographic data, location-based data, phone numbers, email addresses, IDs, home addresses, data or records related to a user's health or level of health (e.g., vital sign measurements, medication information, exercise information), date of birth, or any other identifying or personal information.

[0079] The present disclosure recognizes that the use of such personal information data in the technology of the present invention can be used to benefit users. For example, such personal information data can be used to deliver target content that the user is more interested in. Thus, the use of such personal information data enables users to exercise planned control over the content delivered. In addition, the present disclosure also anticipates other uses of personal information data that are beneficial to users. For example, health and fitness data can be used to provide insights into a user's overall health condition, or can be used as positive feedback for an individual using technology to pursue health goals.

[0080] The present disclosure contemplates that entities responsible for collecting, analyzing, disclosing, transmitting, storing, or otherwise using such personal information data will comply with established privacy policies and / or privacy practices. Specifically, such entities should implement and adhere to privacy policies and practices that are recognized as meeting or exceeding industry or government requirements for maintaining the privacy and security of personal information data. Such policies should be readily accessible to users and should be updated as the collection and / or use of data changes. Personal information from users should be collected for legitimate and reasonable uses of the entity and not shared or sold outside of those legitimate uses. In addition, such collection / sharing should be done with the informed consent of the user. Additionally, such entities should consider taking any necessary steps to safeguard and secure access to such personal information data and to ensure that others with access to personal information data comply with their privacy policies and procedures. Additionally, such entities may subject themselves to third-party assessments to demonstrate their compliance with widely accepted privacy policies and practices. Additionally, policies and practices should be adjusted to account for the specific types of personal information data collected and / or accessed and to apply applicable laws and standards that include specific considerations of the jurisdiction. For example, in the United States, the collection or acquisition of certain health data may be governed by federal and / or state laws, such as the Health Insurance Portability and Accountability Act (HIPAA); while health data in other countries may be subject to other regulations and policies and should be handled accordingly. Thus, different privacy practices for different types of personal data should be maintained in each country.

[0081] Regardless of the foregoing, the present disclosure also contemplates embodiments where a user selectively blocks the use or access of personal information data. That is, the present disclosure contemplates that hardware elements and / or software elements may be provided to prevent or block access to such personal information data. For example, in the case of an advertising delivery service, the inventive technology may be configured to allow a user to select "opt-in" or "opt-out" of participating in the collection of personal information data during or at any time after registering for the service. In another example, a user may choose not to provide emotion-related data for a targeted content delivery service. In another example, a user may choose to limit the length of time that emotion-related data is kept, or to completely prohibit the development of underlying emotional states. In addition to providing "opt-in" and "opt-out" options, the present disclosure also contemplates providing notices related to the access or use of personal information. For example, a user may be notified when downloading an application that their personal information data will be accessed, and then reminded again just before the personal information data is accessed by the application.

[0082] In addition, it is an object of the present disclosure to manage and process personal information data to minimize the risk of unintentional or unauthorized access or use. The risk can be minimized by restricting data collection and deleting data once it is no longer needed. In addition, and when applicable, including in certain health-related applications, data de-identification can be used to protect the privacy of users. De-identification can be facilitated, when appropriate, by removing specific identifiers (e.g., date of birth, etc.), controlling the amount or specificity of the data stored (e.g., collecting location data at the city level rather than at the address level), controlling how the data is stored (e.g., aggregating data among users), and / or other methods.

[0083] Thus, while the present disclosure broadly covers the use of personal information data to implement one or more of the various disclosed embodiments, the present disclosure also contemplates that various embodiments may also be implemented without accessing such personal information data. That is, the various embodiments of the inventive technology will not fail to function properly due to the lack of all or a portion of such personal information data. For example, preferences may be inferred by relying on non-personal information data or an absolute minimum amount of personal information such as the content requested by a device associated with the user, other non-personal information available to the content delivery service, or publicly available information, and content may be selected and delivered to the user based on those inferences.

[0084] For illustrative purposes, the foregoing description uses specific names to provide a thorough understanding of the described embodiments. However, it will be apparent to those skilled in the art that no specific details are required in order to practice the described embodiments. Accordingly, the foregoing description of the specific embodiments described herein is presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to those of ordinary skill in the art that, given the above teachings, many modifications and variations are possible.

Claims

1. A side wall of a housing of a portable electronic device, comprising: an elongated cladding material, the elongated cladding material comprising: titanium, the titanium defining an outer surface of the portable electronic device; aluminum, the aluminum being fixed to the titanium and defining an inner surface of the portable electronic device; a recessed feature defined by the titanium and the aluminum; and a non-metallic portion coupled to the titanium and the aluminum at the recessed feature.

2. The side wall of the housing according to claim 1, wherein, the recessed feature includes a hole extending through the side wall of the housing.

3. The side wall of the housing according to claim 1, wherein, the recessed feature includes at least one of a groove or a tooth.

4. The side wall of the housing according to claim 1, wherein, the non-metallic portion includes a polymer.

5. The side wall of the housing according to claim 1, wherein, the outer surface is curved.

6. The side wall of the housing according to claim 1, wherein, the titanium covers the aluminum to prevent the aluminum from being exposed to the external environment of the portable electronic device.

7. The side wall of the housing according to claim 1, wherein, the non-metallic portion is directly coupled to the aluminum and the titanium.

8. The side wall of the housing according to claim 1, wherein, the non-metallic portion is coupled to the aluminum and the titanium via an adhesive.

9. A housing of an electronic device, comprising: a side wall, the side wall comprising: titanium, the titanium defining an outer surface; and aluminum, the aluminum being directly fixed to the titanium and defining a mating feature; and a polymer portion, the polymer portion being coupled to the aluminum at the mating feature.

10. The housing according to claim 9, wherein, the mating feature includes at least one of a hole or a recess in the side wall.

11. The housing according to claim 9, wherein, the polymer portion is mechanically interlocked with the mating feature.

12. The housing according to claim 9, wherein, the polymer portion includes plastic.

13. The housing according to claim 9, wherein, the side wall includes an elongated structure.

14. The housing according to claim 13, wherein: the mating feature is a first mating feature; and the housing includes a second mating feature.

15. The housing according to claim 14, wherein: the polymer portion is a first polymer portion; and the housing includes a second polymer portion, the second polymer portion being coupled to the aluminum at the second mating feature.

16. A housing component for an electronic device, comprising: a part, the part comprising: a titanium portion, the titanium portion defining a curved outer surface; an aluminum portion, the aluminum portion being fixed to the titanium portion and defining: an inner surface opposite to the outer surface; and a mating feature, the mating feature extending from the inner surface into the aluminum portion; and a non-metallic material, the non-metallic material being coupled to the part and extending into the mating feature.

17. The housing component according to claim 16, wherein, the mating feature extends into the titanium portion.

18. The housing component according to claim 17, wherein, The non-metallic material contacts the aluminum portion and the titanium portion.

19. The housing component according to claim 16, wherein, the non-metallic material comprises a polymer.

20. The housing component according to claim 19, wherein, the non-metallic material comprises a plastic.

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