Co-sintered ceramic for electronic devices

Patent metadata

Field	Value
Publication number	US-10071539-B2
Application number	US-201514864618-A
Country	US
Kind code	B2
Filing date	Sep 24, 2015
Priority date	Sep 30, 2014
Publication date	Sep 11, 2018
Grant date	Sep 11, 2018

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.

First claim

What is claimed is:

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.

Assignees

• Apple Inc

Inventors

• Matsuyuki Naoto
• Ness Trevor J
• Nazzaro David I

Classifications

• B28B1/002

  assembled from preformed elements · CPC title

• C04B2235/6022

  Injection moulding · CPC title

• H04M1/0202

  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 title

• B32B18/00 Primary

  Layered products essentially comprising ceramics, e.g. refractory products · CPC title

• C04B2235/6023

  Gel casting · CPC title