Co-sintered ceramic for electronic devices

• US 10,071,539 B2
• Filed: 09/24/2015
• Issued: 09/11/2018
• Est. Priority Date: 09/30/2014
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Matsuyuki, Naoto, Ness, Trevor J., Nazzaro, David I.
• Primary Examiner(s): Moore, Margaret G
• Application Number:
  US14/864,618
• Publication Number:
  US 20160090326A1
• Time in Patent Office: 1,083 Days
• CPC Class Codes: B28B 1/002 assembled from preformed elements
• CPC Class Codes: B28B 1/008 made from two or more materials having different characteristics or properties casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00
• CPC Class Codes: B28B 7/0088 Moulds in which at least one surface of the moulded article serves as mould surface, e.g. moulding articles on or against a previously shaped article, between previously shaped articles
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: C04B 2235/602 Making the green bodies or pre-forms by moulding
• CPC Class Codes: C04B 2235/6022 Injection moulding
• CPC Class Codes: C04B 2235/6023 Gel casting
• CPC Class Codes: C04B 2235/9615 Linear firing shrinkage
• CPC Class Codes: C04B 2237/343 Alumina or aluminates
• CPC Class Codes: C04B 2237/348 Zirconia, hafnia, zirconates or hafnates
• CPC Class Codes: C04B 35/645 Pressure sintering
• CPC Class Codes: H04M 1/0202 Portable telephone sets, e.g. cordless phones, mobile phones or bar type handsets constructional features of telephone transmitters or receivers, e.g. of speakers or microphones H04M1/03
• CPC Class Codes: H04M 1/0266 for a display module assembly

Abstract

A ceramic structure and methods for making the ceramic structure are disclosed. Multiple parts may be molded; the parts may be molded from the same or different ceramic materials. The parts may be formed in the same mold and may be adjacent to and/or attached to one another as a result of molding. The parts may be placed in a sintering furnace and sintered simultaneously. Simultaneously sintering the parts forms a unitary structure from the parts.

Claims

1. A method for manufacturing a ceramic housing for a portable electronic device, comprising:

forming a first part from a first ceramic material that is optically opaque to define a partially enclosed volume and an opening into the partially enclosed volume;

forming a second part from a second ceramic material that is optically transparent;

positioning the second part over the opening of the first part; and

sintering the first part and the second part, thereby fusing the first part to the second part to form the ceramic housing.

2. The method of claim 1, wherein:

forming the first part from the first ceramic material comprises molding the first part from the first ceramic material; and

forming the second part from the second ceramic material comprises molding the second part from the second ceramic material, such that the second part abuts the first part.

3. The method of claim 1, wherein simultaneously sintering the first part and second part comprises co-sintering the first part and second part in a sintering furnace.

4. The method of claim 3, wherein co-sintering the first part and second part causes first ceramic grains of the first ceramic material to migrate to the second part.

5. The method of claim 3, wherein co-sintering the first part and second part causes the second ceramic material to dope the first part.

6. The method of claim 1, wherein fusing the first part to the second part bonds the first and second parts without a visible seam.

7. The method of claim 1, further comprising joining the ceramic housing to an end cap to form an exterior of an electronic device.

8. The method of claim 1, wherein the first ceramic material and the second ceramic material include different structural properties.

9. A housing for a portable electronic device, comprising:

a first part formed from a first ceramic material that is opaque and defines an opening; and

a second part formed from a second ceramic material that is transparent and is positioned at least partially within the opening of the first part;

wherein

the first and second parts are fused together during sintering.

10. The housing of claim 9, wherein:

the portable electronic device comprises an optical component; and

the second part defines a window for the optical component.

11. The housing of claim 9, wherein:

the first ceramic material is zirconia; and

the second ceramic material is alumina.

12. The housing of claim 10, wherein:

the optical component is a display; and

the second part defines a cover for the display.

13. The housing of claim 9, further comprising an end cap affixed to the first and the second part.

14. The housing of claim 9, wherein:

the first and second parts cooperate to form a continuous external surface of the housing.

15. The housing of claim 9, wherein the first part defines a support for the second part.

16. A method for forming a co-sintered structure, comprising:

molding, using first mold piece and a second mold piece, a first part from a first ceramic slurry;

co-molding to the first part, using the first mold piece and a third mold piece, a second part from a second ceramic slurry; and

co-sintering the first and second parts, thereby forming the co-sintered structure, the first part being optically opaque and the second part being optically transparent and positioned at least partially within an opening defined within the first part.

17. The method of claim 16, further comprising supporting at least some of the second ceramic slurry with the first part.

18. The method of claim 16, wherein:

the first ceramic slurry is a zirconia slurry; and

the second ceramic slurry is an alumina slurry.

19. The method of claim 16, further comprising, prior to co-molding, depositing the second ceramic slurry in a mold cavity defined by the third mold piece and first part.

20. The method of claim 16, wherein co-sintering the first and second parts shrinks the first and second parts.

21. The method of claim 20, further comprising controlling shrinkage of the first and second parts during the co-sintering operation.