Apple has always hated seams and joints in their devices. Now the company is trying to get a patent for unibody design for their iconic earphones. The plan includes welding the parts ultrasonically. This might make you think that that the body would be made of metal but you are wrong. The design would consist of multiple plastic parts welded together.
This is where ultrasonic welding plays its role. This welding only melts the contact points between the parts. As we weld, the plastic melts at the junction and forms a bond. Obvious question one would ask is “Why not use some special glue?” Apple says ultrasonic welding produces smoother edges, without seams.
Ultrasonic welding is in fact not a new thing. Earlier USPTO published an even more complex welding. They welded metal with plastic. The problem here is the difference in the melting points of the two materials. However, Apple proposed to make grooves in the metal, as the plastic melts it would fill in the grooves and form a bond. Rumors say that Apple is using this technique for the new iPhone body.
In previous attempts Apple tried to make their computers with unibody. The result was a very slim design with a more strength and durability. This made their computer lighter. So we can expect these new earbuds to be outstanding.