Interlocking flexible segments formed from a rigid material

Abstract

A method for creating a flexible portion or bending portion within a rigid structure. The method can also be used for creating a flexible structure from a rigid material. The method includes providing a substantially rigid material, such as, but not limited to, metals, alloys, hard plastics, and the like, and selectively removing portions of the rigid material defining a geometric pattern in the rigid material. A bending radius of the flexible portion is defined by the geometric pattern. The rigid structure may be used to create an enclosure, a cover for an electronic device, one or more hinges, or the like.

What is claimed is: 
     
         1 . A method for creating a flexible portion in a rigid material, comprising:
 providing a substantially rigid material; and   selectively removing portions of the rigid material defining a geometric pattern in the rigid material, the geometric pattern defining the flexible portion; wherein   a bend radius of the flexible material is defined by the geometric pattern.   
     
     
         2 . The method of  claim 1 , wherein the geometric pattern comprises:
 at least two flex apertures; and   at least two sidewalls bordering and defining the flex apertures; wherein   the sidewalls are angled between a first surface of the rigid material and a second surface of the rigid material.   
     
     
         3 . The method of  claim 1 , wherein the flexible structure includes a first flexible portion having a first bend radius and a second flexible portion having a second flexible portion. 
     
     
         4 . The method of  claim 1 , wherein selectively removing portions of the rigid material comprises at least one of heating the rigid material with a laser or using electrical discharge machining. 
     
     
         5 . The method of  claim 1 , wherein at least one surface of the rigid material is substantially planar. 
     
     
         6 . The method of  claim 1 , wherein the rigid material is a three-dimensional shape. 
     
     
         7 . A method for creating an enclosure for an electronic device comprising:
 providing a rigid material; and   removing sections of the rigid material to create a geometric pattern.   
     
     
         8 . The method of  claim 7 , wherein the operation of providing a rigid material further comprises metal molding the rigid material. 
     
     
         9 . The method of  claim 7 , wherein removing sections of the rigid material is performed by a laser cutting device. 
     
     
         10 . An enclosure formed of a substantially rigid material comprising:
 a first plurality of flex apertures defined within the rigid material along a first row;   a second plurality of flex apertures defined within the rigid material along a second row;   
       wherein
 the second row is positioned below the second row; 
 the first plurality of flex apertures are misaligned with the second plurality of flex apertures such that a first end of each of the first plurality of flex apertures is in a different vertical plane from a first end of each of the second plurality of flex apertures; and 
 when a bending force is applied to one of the first row or the second row, the first plurality of flex apertures and the second plurality of flex apertures vary in shape or dimension, allowing the rigid material to bend. 
 
     
     
         11 . The enclosure of  claim 10 , wherein the first plurality of flex apertures and the second plurality of flex apertures are substantially diamond shaped. 
     
     
         12 . A housing of a substantially rigid material, comprising:
 a first plurality of interlocking features defined within the rigid material;   a second plurality of interlocking features defined within the rigid material; and   a plurality of flex apertures defined between the first plurality of interlocking features and the second plurality of interlocking features to separate the first plurality of interlocking features from the second plurality of interlocking features; wherein   the first plurality of interlocking features is movable relative to the second plurality of interlocking features.   
     
     
         13 . The housing of  claim 12 , wherein the first plurality of interlocking features and the second plurality of interlocking features are substantially frustum shaped. 
     
     
         14 . The housing of  claim 12 , wherein each of the first plurality of interlocking features include at least one sidewall, wherein the at least one sidewall changes in angular orientation from a first surface of the rigid material to a second surface of the rigid material. 
     
     
         15 . The housing of  claim 14 , wherein each of the second plurality of interlocking features include at least one sidewall, wherein the at least one sidewall changes in angular orientation from the first surface of the rigid material to a second surface of the rigid material. 
     
     
         16 . A method of manufacturing a flexible component, comprising:
 providing a substantially rigid material; and   removing portions of the rigid material to create a plurality of flex apertures, wherein the flex apertures are defined by interlocking features adjacent each other and spaced apart by the flex apertures; wherein   each interlocking feature has at least one sidewall and an angle of the sidewall determines a radial bend of the rigid material; and   the rigid material is non-cylindrical.   
     
     
         17 . The method of  claim 16 , wherein the rigid material is planar. 
     
     
         18 . The method of  claim 16 , wherein a geometric pattern is defined in the rigid material by the plurality of flex apertures. 
     
     
         19 . The method of  claim 18 , wherein a first side of the rigid material has a first geometric pattern and the second side of the rigid material has a second geometric pattern. 
     
     
         20 . The method of  claim 16 , wherein removing portions of the rigid material is done by one of a multi-axis laser or electrical discharge machining.