Interlock features of a portable electronic device

Abstract

An electronic device having multiple housing components interlocked together by a molded material is disclosed. In order to provide interlocking surfaces for the molded material, the housing components can include various geometries designed to receive and retain the molded material such that the housing components are secured with one another. For example, a first housing part can undergo several material removal operations to form multiple ribs, each with through holes. When the molded material extends along the ribs and into the through holes, the molded material cures and interlocks with the first housing part. A second housing part can include several stepped indentions that receive the molded material. Also, a third housing part can include a dovetail indention to receive the molded material such that the first and second housing parts interlock with the third housing part. The indentions can provide retention in three dimensions to protect against decoupling.

What is claimed is: 
     
         1 . An enclosure for a portable electronic device, the enclosure comprising:
 a first metal portion that includes side walls having an interlocking feature;   a second metal portion that includes a bottom wall having an indention that together with a portion of the side walls define a channel; and   a dielectric element that fills the channel and the interlocking feature so as to interlock and electrically isolate the first and second metal portions from each other, wherein the dielectric element defines an exterior surface of the enclosure.   
     
     
         2 . The enclosure of  claim 1 , wherein the interlocking feature is a small-scale interlock. 
     
     
         3 . The enclosure of  claim 1 , wherein the interlocking feature is a through-hole that extends between external and internal surfaces of the first metal portion. 
     
     
         4 . The enclosure of  claim 1 , wherein the dielectric element includes a first dielectric element and a second dielectric element. 
     
     
         5 . The enclosure of  claim 4 , wherein the second dielectric element further defines the exterior surface of the enclosure, and the first dielectric element is concealed by the second dielectric element and the first and second metal portions. 
     
     
         6 . The enclosure of  claim 5 , wherein the first and second dielectric elements define a radio-frequency (RF) transparent window capable of allowing an RF signal to pass therethrough. 
     
     
         7 . The enclosure of  claim 1 , wherein the first and second metal portions are separated by the channel. 
     
     
         8 . A housing for a portable electronic device, the housing comprising:
 a first housing portion having a side wall that includes a surface feature;   a second housing portion that includes a back wall that together with a portion of the side wall define a channel, wherein the channel is disposed between the first and second housing portions; and   a third housing portion formed of a dielectric material that fills the surface feature and the channel so as to interlock the first and second housing portions and define a radio-frequency (RF) transparent window capable of allowing an RF signal to pass therethrough.   
     
     
         9 . The housing of  claim 8 , wherein the third housing portion electrically isolates the first and second housing portions. 
     
     
         10 . The housing of  claim 8 , wherein the surface feature is a through-hole or a structural rib. 
     
     
         11 . The housing of  claim 8 , wherein the third housing portion defines an exterior surface of the housing. 
     
     
         12 . The housing of  claim 8 , wherein the first housing portion is coupled to an RF antenna configured to transmit the RF signal through the RF transparent window. 
     
     
         13 . The housing of  claim 8 , wherein the third housing portion includes a first dielectric element and a second dielectric element, and the second dielectric element conceals the first dielectric element. 
     
     
         14 . The housing of  claim 13 , wherein the first dielectric element mechanically interlocks the first and second housing portions. 
     
     
         15 . A housing for a portable electronic device, the housing comprising:
 a corner housing portion including a small-scale interlock feature;   a bottom housing portion that together with the corner housing portion defines a channel, wherein the corner and bottom housing portions are separated by the channel; and   a dielectric element that fills the channel and the small-scale interlock feature so as to mechanically interlock and electrically isolate the corner and bottom housing portions.   
     
     
         16 . The housing of  claim 15 , wherein the dielectric element defines an exterior surface of the housing. 
     
     
         17 . The housing of  claim 15 , wherein the small-scale interlock feature is a through-hole or a structural rib. 
     
     
         18 . The housing of  claim 15 , wherein the dielectric element includes a first dielectric element and a second dielectric element, and the second dielectric element conceals the first dielectric element. 
     
     
         19 . The housing of  claim 18 , wherein the first and second dielectric elements define a radio-frequency (RF) transparent window. 
     
     
         20 . The housing of  claim 15 , wherein the dielectric element is a dual state material.