Anodizing and pre-anodizing processes based on incoming laser textured part

Patent metadata

Field	Value
Publication number	US-10590559-B2
Application number	US-201514835541-A
Country	US
Kind code	B2
Filing date	Aug 25, 2015
Priority date	Mar 13, 2015
Publication date	Mar 17, 2020
Grant date	Mar 17, 2020

Abstract

Substrates having laser textured surfaces and methods for forming the same are described. The methods involve using a laser to form three-dimensional features on a surface of the substrate. The laser three-dimensional features can be designed to interact with incident light to create unique visual effects. In some embodiments, the substrate is further treated with a pre-anodizing process and an anodizing process to form a protective metal oxide coating. In some cases, the type of pre-anodizing and anodizing process are chosen based on the geometry of the three-dimensional features and to enhance the visual effects.

First claim

What is claimed is:

1. A method of forming a housing for a portable electronic device, the method comprising:
forming surface features on a planar surface of a metal substrate by using a laser, wherein the surface features are arranged according to a regular and repeating pattern, wherein at least one of the surface features includes a cavity defined by walls that (i) extend from the planar surface and into the metal substrate to a depth of at least 10 micrometers, and (ii) include a first reflective micro-feature and a second reflective micro-feature; and
forming an anodized layer from the metal substrate such that the anodized layer overlays the surface features, wherein the first and second reflective micro-features are oriented at first and second angles, respectively, relative to an external surface of the anodized layer.

2. The method of claim 1 , wherein using the laser to form the surface features comprises:
melting a portion of the metal substrate; and
resolidifying the melted portion of the metal substrate.

3. The method of claim 2 , wherein the laser ablates the portion of the metal substrate.

4. The method of claim 2 , wherein the walls are formed of resolidifed metal.

5. The method of claim 1 , wherein the housing is characterized as having a uniform thickness, and a thickness of the metal substrate and a thickness of the anodized layer contribute to the uniform thickness.

6. The method of claim 1 , wherein the surface features have widths between 100 micrometers to 1 millimeter.

7. A housing for a portable electronic device, the housing comprising:
a metal substrate having a planar external surface including a repeated and regular pattern of surface features, wherein at least one of the surface features includes a cavity defined by walls that (i) extend from the planar external surface and into the metal substrate to a depth of at least 10 micrometers, and (ii) include a first reflective micro-feature and a second reflective micro-feature; and
an anodized layer overlaying the surface features, wherein the first and second reflective micro-features are oriented relative to an external surface of the anodized layer at a first angle and a second angle different than the first angle.

8. The housing of claim 7 , wherein the housing is characterized as having a uniform thickness, and a thickness of the metal substrate and a thickness of the anodized layer contribute to the uniform thickness.

9. The housing of claim 7 , wherein each of the surface features has a width between 100 micrometers to 1 millimeter.

10. The housing of claim 7 , wherein the first and second reflective micro-features are included on one of the walls.

11. The housing of claim 7 , wherein the anodized layer is transparent to visible light that is incident at the external surface of the anodized layer so that the reflective first and second micro-features are viewable through the external surface of the anodized layer.

12. The housing of claim 7 , wherein portions of the planar external surface of the metal substrate are parallel to the external surface of the anodized layer.

13. The housing of claim 7 , wherein the anodized layer is characterized as having a shape that is capable of focusing visible light towards the first and second reflective micro-features so as to impart the metal substrate with a sparkling appearance.

14. The housing of claim 7 , wherein the repeated and regular pattern of surface features is formed by ablating the planar external surface of the metal substrate with a laser.

15. The housing of claim 7 , wherein visible light that passes through the anodized layer is reflected by the first and second reflective micro-features at varying angles.

16. A housing for a portable electronic device, the housing comprising:
a metal substrate including a planar surface having a regular and repeating pattern of reflective features, wherein at least one of the reflective features includes a cavity defined by walls that (i) extend from the planar surface and into the metal substrate to a depth of at least 10 micrometers, and (ii) include a first reflective micro-feature and a second reflective micro-feature; and
an anodized layer overlaying the reflective features, wherein the first and second reflective micro-features are oriented at first and second different angles, respectively, relative to an external surface of the anodized layer.

17. The housing of claim 16 , wherein the external surface of the anodized layer is parallel to portions of the planar surface of the metal substrate.

18. The housing of claim 17 , wherein the housing is characterized as having a uniform thickness, and a thickness of the metal substrate and a thickness of the anodized layer contribute to the uniform thickness.

19. The housing of claim 16 , wherein each of the surface features have a width between 100 micrometers to 1 millimeter.

Assignees

• Apple Inc

Inventors

• Maloney Max A
• Nashner Michael S
• Novak Sean R

Classifications

• B44C1/228

  by laser radiation · CPC title

• C25D11/04

  of aluminium or alloys based thereon · CPC title

• B23K26/354

  by melting · CPC title

• C25D11/16 Primary

  Pretreatment {, e.g. desmutting} · CPC title

• B23K26/3576

  Diminishing rugosity, e.g. by grinding, polishing or smoothing · CPC title