New Apple Technology to Produce Seamless Metal iPhone Case

(MoneyWatch)  Back in October, Apple's new process for making aluminum computer cases out of a single block received attention, and rightly so. No screws, stronger units, lighter weight, and cheap costs are a big plus for consumer and manufacturer alike. We should have known that wouldn't have been the end of new case manufacturing. Apparently Apple has developed a related process to make handheld computer cases out of extruded tubing, creating the possibility for a seamless iPhone or iPod case.

Patent 7,515,431, granted on Tuesday, describes the concept. Apple extrudes an aluminum tube to make an open ended rectangular box with internal rails that run the length of the tube and an access point (the screen has to show somewhere) cut into one side. Apple can cut sections from a stretch of tubing, with each section becoming the housing for a single device. The rails make it possible to slide such components as a "user interface assembly" and other operational subassemblies into place. Elements are then secured to the tube, meaning that Apple can avoid any screws showing up on the surface of the finished device. Slide a cap on each end and you're good to go. The patent also covers variations, including using a retaining plate that snaps into place.

To put it differently, imagine an iPhone or iPod in a single piece, brushed aluminum case, maybe with connectors in the bottom cap for ease of assembly. Kudos to Apple for yet another smart display of industrial engineering, increasing consumer design appeal, simplifying assembly, and lowering costs all at the same time.

As my colleague Michael Hickins points out, Apple has a big order in for flash memory. Could that be another sign that it expects to come out with something new that has massive sales appeal? And given that Apple may be near the saturation point for teen adoption of iPods, the company will need to do something to keep the momentum going. Having a cool new design might inspire many to ditch an older unit for something shiny and new.