Yttria-sensitized zirconia

• US 10,624,217 B2
• Filed: 08/08/2019
• Issued: 04/14/2020
• Est. Priority Date: 09/21/2016
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Matsuyuki, Naoto, Memering, Dale N., Waniuk, Theodore A., Takagi, Kazuya, Ely, Colin M.
• Primary Examiner(s): Aughenbaugh, Walter
• Application Number:
  US16/535,810
• Publication Number:
  US 20190364674A1
• Time in Patent Office: 250 Days
• CPC Class Codes: B24C 1/04 for treating only selected parts of a surface, e.g. for carving stone or glass
• CPC Class Codes: B24C 1/06 for producing matt surfaces, e.g. on plastic materials, on glass
• CPC Class Codes: B24C 1/08 for polishing surfaces, e.g. smoothing a surface by making use of liquid-borne abrasives
• CPC Class Codes: B24C 11/00 Selection of abrasive materials or additives for abrasive blasts polishing compositions C09G
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: C04B 2235/3225 Yttrium oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/76 Crystal structural characteristics, e.g. symmetry
• CPC Class Codes: C04B 2235/765 Tetragonal symmetry
• CPC Class Codes: C04B 2235/963 Surface properties, e.g. surface roughness
• CPC Class Codes: C04B 35/48 based on zirconium or hafnium oxides, zirconates, zircon or hafnates
• CPC Class Codes: C04B 35/486 Fine ceramics
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/53 involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete C04B41/0036 - C04B41/0054 take precedence
• CPC Class Codes: C04B 41/91 involving the removal of part of the materials of the treated articles, e.g. etching
• CPC Class Codes: H01L 23/06 characterised by the material of the container or its electrical properties
• 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 1/0283 for providing a decorative aspect, e.g. customization of casings, exchangeable faceplate
• CPC Class Codes: H04M 1/18 Telephone sets specially adapted for use in ships, mines, or other places exposed to adverse environment H04M1/19 takes precedence
• CPC Class Codes: H04M 1/185 Improving the rigidity of the casing or resistance to shocks
• CPC Class Codes: H05K 5/0004 comprising several parts forming a closed casing
• CPC Class Codes: H05K 5/0017 : with operator interface units
• CPC Class Codes: H05K 5/02 : Details
• CPC Class Codes: H05K 5/0247 : Electrical details of casings, e.g. terminals, passages for cables or wiring

Abstract

A housing for a portable electronic device is disclosed. The housing is composed of yttria-sensitized zirconia. Yttria-sensitized zirconia has from about 1.5 to about 2.5 mole percent yttria, and more typically about 2 mole percent yttria, and most typically 2 mole percent yttria, in zirconia. Yttria-sensitized zirconia is both tough and able to limit the formation and propagation of micro-cracks. Methods for manufacturing yttria-sensitized zirconia composed housings are also disclosed.

Claims

1. A housing for an electronic device, comprising:

zirconia and from 1.5 mole percent to 2.5 mole percent yttria;

a first portion containing a first amount of monoclinic crystals defining a first surface having a first surface roughness; and

a second portion containing a second amount of monoclinic crystals that exceeds the first amount defining a second surface having a second surface roughness greater than the first surface roughness.

2. The housing of claim 1, wherein the first surface comprises an exterior surface of the electronic device.

3. The housing of claim 2, wherein the first surface comprises a polished surface.

4. The housing of claim 1, wherein the second surface comprises an interior surface of the electronic device.

5. The housing of claim 4, wherein the second surface comprises a roughened surface.

6. The housing of claim 5, wherein the second surface comprises a media blasted surface.

7. The housing of claim 1, wherein the second surface roughness is from 0.05 μ

m to 0.4 μ

m.

8. The housing of claim 7, wherein the second surface roughness is from 0.08 μ

m to 0.35 μ

m.

9. The housing of claim 1, wherein a portion of the housing connecting the first portion to the second portion comprises tetragonal zirconia crystals.

10. The housing of claim 1, wherein the first portion and the second portion comprise monoclinic and tetragonal zirconia crystals.

11. The housing of claim 1, wherein the housing comprises 2 mole percent yttria.

12. The housing of claim 1, wherein the housing is composed of zirconia and from 1.5 mole percent to 2.5 mole percent yttria.

13. The housing of claim 1, wherein the second portion comprises a curved or contoured shape.

14. The housing of claim 1, wherein the housing at least partially defines an enclosed volume including at least one electronic component.

15. The housing of claim 14, further comprising a display coupled to the housing.

16. A housing for an electronic device, comprising:

a body comprising yttria-sensitized zirconia and defining a first surface and a second surface;

the portion of the body defining the first surface containing a higher percentage of monoclinic zirconia crystals than the portion of the body defining the second surface.

17. The housing of claim 16, wherein the yttria-sensitized zirconia comprises zirconia and from 1.5 mole percent to 2.5 mole percent yttria.

18. The housing of claim 16, wherein the first surface at least partially defines an exterior surface of the electronic device and the second surface at least partially defines an enclosed volume.

19. The housing of claim 18, wherein a distance between the first surface and the second surface is less than 10 mm.

20. The housing of claim 16, wherein the portion of the body defining the second surface comprises a corner or an edge.