PATENT DOCUMENT

Publication Number: US-10200516-B2
Application Number: US-201414472230-A
Country: US
Kind Code: B2

Title: Interlocking ceramic and optical members

Abstract:
Interlocking first member and optical members and methods of their manufacture. A component formed from an interlocking first member and optical member, where the first member includes a recess formed within a surface and the optical member is disposed in the recess. The recess of the first member may include a recess geometry and the optical member may include a member geometry that may correspond to the recess geometry. Additionally, the interlocking component formed from the first member and optical member may be formed by a coupling process. The coupling process may include sintering the first member and the optical member, bonding the optical member to the first member or providing a compression-load or fit between the first member and the optical member.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a housing defining an exterior surface and a recess having a recess geometry, the housing formed from a first ceramic material having a first coefficient of thermal expansion, the first ceramic material selected from the group consisting of: alumina, zirconia, carbides, borides, nitrides, and silicides; and 
 an optical member disposed in the recess and formed from a second ceramic material having a second coefficient of thermal expansion that is different than the first coefficient of thermal expansion, the optical member having a member geometry and configured to allow light into the housing through the recess, wherein:
 the recess geometry includes an angled protrusion extending into a volume defined by the recess; and 
 the angled protrusion mechanically engages the member geometry such that the ceramic member prevents movement of the optical member within the recess along a first direction toward the exterior surface and along a second direction away from the exterior surface. 
 
 
     
     
       2. The electronic device of  claim 1 , wherein the housing and optical member define a gap-free interface. 
     
     
       3. The electronic device of  claim 2 , wherein:
 the housing defines:
 a first width at the exterior surface; 
 a second width at a depth within the recess, the second width less than the first width; and 
 
 the angled protrusion is defined by a tapered surface extending between the first and second widths. 
 
     
     
       4. The electronic device of  claim 1 , wherein the housing and the optical member expand toward one another at different rates in response to a heat input. 
     
     
       5. The electronic device of  claim 1 , wherein the optical member one of:
 protrudes beyond the exterior surface of the housing; or 
 recedes below the exterior surface of the housing. 
 
     
     
       6. The electronic device of  claim 1 , wherein the second ceramic material is a sapphire glass material. 
     
     
       7. The electronic device of  claim 1 , further comprising:
 a securement layer configured to affix the optical member and the housing, the securement layer comprising at least one of an adhesive, a chemical bonding agent, or a sealant. 
 
     
     
       8. The electronic device of  claim 7 , wherein the securement layer includes at least one of a zirconia or a ceramic slurry. 
     
     
       9. The electronic device of  claim 1 , wherein the optical member includes multiple distinct members joined at a contact surface. 
     
     
       10. The electronic device of  claim 9 , further comprising a transparent member positioned between the multiple members;
 wherein the transparent member includes at least one of a logo, an optically transparent adhesive or a texture adhesive. 
 
     
     
       11. The electronic device of  claim 1 , wherein an inner surface of the housing defining the recess is coated with an ink. 
     
     
       12. The electronic device of  claim 1 , wherein the housing includes at least two distinct components coupled together using a bonding agent. 
     
     
       13. The electronic device of  claim 1 , further comprising a retention member coupled to the optical member, the retention member positioned adjacent the housing and outside of the recess. 
     
     
       14. The electronic device of  claim 13 , wherein the retention member is larger than the recess of the ceramic member. 
     
     
       15. A component, comprising:
 a first member comprising a recess formed within a surface, the recess comprising:
 a first portion defining a first interface surface; and 
 a second portion defining a second interface surface that differs from the first interface surface, the first and second interface surfaces adjoining at an edge within a volume defined by the recess; and 
 
 an optical member having a first, distinct joined member and a second, distinct joined member, the first, distinct joined member being disposed in the first portion and the second distinct, joined member being disposed in the second portion, the first, distinct joined member affixed to the second, distinct joined member within the recess, 
 wherein the first interface surface mechanically engages the first, distinct joined member and the second interface surface mechanically engages the second, distinct joined member such that the edge is positioned between the first and second, distinct joined members and prevents movement of the optical member along a first direction toward the surface and a second direction away from the surface. 
 
     
     
       16. The component of  claim 15 , further comprising:
 a securement layer positioned between the first, distinct joined member and the second, distinct joined member, the securement layer configured to affix the first, distinct joined member of the optical member to the second, distinct joined member of the optical member within the recess. 
 
     
     
       17. The component of  claim 15 , wherein at least one of:
 a size of the first member is configured to increase in response to a heat input such that a width of the recess decreases; or 
 a width of the optical member is configured to increase in response a heat input. 
 
     
     
       18. The component of  claim 15 , wherein the securement layer comprises at least one of:
 an adhesive; 
 a chemical bonding agent; or 
 a sealant. 
 
     
     
       19. The component of  claim 15 , wherein the optical member is formed from a sapphire glass material. 
     
     
       20. The component of  claim 15 , wherein:
 the first, distinct joined member defines a first geometry comprising:
 a first width; 
 a second width that is less than the first width; and 
 a first tapered surface extending between the first and second widths; 
 
 the second, distinct joined member defines a second geometry comprising:
 a third width; 
 a fourth width that is less than the third width; and 
 a second tapered surface extending between the third and fourth widths; 
 
 the first interface surface corresponds to the first geometry; and 
 the second interface surface corresponds to the second geometry. 
 
     
     
       21. The component of  claim 20 , wherein:
 the first portion abuts the second portion; and 
 the second width is substantially the same as the fourth width. 
 
     
     
       22. An electronic device, comprising:
 a housing formed from a first ceramic material having a first coefficient of thermal expansion, the first ceramic material selected from the group consisting of: alumina, zirconia, carbides, borides, nitrides, and silicides, the housing defining a recess extending into an enclosed volume and a first engagement feature within the recess; and 
 an optical member formed from a second ceramic material and having a second coefficient of thermal expansion that is less than the first coefficient of thermal expansion, the optical member positioned within the recess and having a second engagement feature contacting the first engagement feature, wherein 
 the first engagement feature prevents movement of the optical member both into and away from the enclosed volume of the housing. 
 
     
     
       23. The electronic device of  claim 22 , wherein:
 the housing defines an exterior surface of the electronic device; 
 the recess extends between the exterior surface and the enclosed volume; and 
 the optical member is a lens positioned along the exterior surface. 
 
     
     
       24. The electronic device of  claim 22 , wherein:
 the first ceramic material is opaque; and 
 the second ceramic material is translucent, thereby defining a light path into the enclosed volume through the recess. 
 
     
     
       25. The electronic device of  claim 22 , wherein:
 the first engagement feature is a protruding portion of a sidewall of the housing that defines the recess; and 
 the second engagement feature is a groove defined by a side surface of the optical member. 
 
     
     
       26. The electronic device of  claim 22 , wherein the optical member comprises multiple, distinct layers of the second ceramic material connected to one another. 
     
     
       27. The electronic device of  claim 26 , wherein at least one of the multiple, distinct layers of the second ceramic material is positioned at least partially outside of the recess.

Description:
TECHNICAL FIELD 
     The embodiments described herein generally relate to ceramic components and, more particularly, to interlocking ceramic and optical members and techniques for manufacturing the same. 
     BACKGROUND 
     Ceramic components are useful in a wide array of products due to their physical properties and characteristics. For example, ceramic and ceramic-based materials typically have high strength and light weight. 
     Because some ceramics are optically opaque, it is often useful to remove material to form holes to provide an optical window for other components, particularly those requiring an optical stimulus (e.g., cameras) or those generating a visual stimulus (e.g., display or light source). One solution is to insert an optical member into a hole formed in the ceramic material. 
     However, conventional methods of inserting optical members into a ceramic housing rely on the use of adhesives or other bonding agents for mechanical integrity, or may require the use of additional structures, such as bezels. Some conventional methods of inserting optical members into a ceramic material may result in a product having a potentially weak region around the optical member. In addition, some conventional methods may result in unsatisfactory environmental permeability, which may increase the risk of ingress of water or debris. While the permeability may be improved by forming a bezel over the region, the use of bezels and other structures may increase the size and weight of the device, and may also require a relatively large amount of surface area. 
     SUMMARY 
     Generally, embodiments discussed herein relate to ceramic components, more particularly to interlocking ceramic and optical members, and methods of their manufacture. In particular, the invention relates to an interlocking ceramic housing (member) and optical member, where the ceramic housing may include a recess formed within a surface, and the optical member may be disposed in the recess. The recess of the ceramic housing and the optical member may have geometries that are configured to mechanically interlock when the optical member is disposed in the recess. In one example, the recess may include a geometry including a first width at the surface and a second width at a depth within the recess, where the first width may be less than the second width, and where the component may be formed by sintering. In certain embodiments, the ceramic housing may have a higher coefficient of thermal expansion than the optical member, and the optical member may also be compression-loaded after sintering of the ceramic housing. 
     In some embodiments, the geometry of the recess may include an undercut geometry, tapered geometry, or counterbored geometry with respect to the surface. In additional embodiments, the geometry of the optical member may correspond to the geometry of the recess. The geometry of the optical member may, in some embodiments, be protruding with respect to the surface or recessed with respect to the surface. 
     In other embodiments, the optical member may include a translucent, transparent, or optically clear material. This material may be one that retains its shape at a temperature of 1400° C., and in certain embodiments may be, for example, sapphire glass. In some embodiments, the optical member may include multiple segments, which may be arranged in a layered or sandwiched arrangement, and may optionally include a transparent member between the segments, for example one or more of an optical or visual material. The optical member may include or be used in one or more of a window, control, or display. 
     In additional embodiments, the housing may include multiple segments. The inner surface of the recess on the housing may also be coated with ink. In yet another embodiment, the component may further include an adhesive, chemical bonding agent, or sealant disposed between the recess and the optical member, which in some embodiments may be zirconia or ceramic slurry. In some embodiments, the composition may be water resistant or water proof. 
     Embodiments of the invention also relate to methods of manufacturing an interlocking ceramic and optical member. The methods may include disposing an optical member into the recess of a ceramic housing having a recess formed within a surface, sintering the ceramic housing to reduce the size of said recess, and cooling the housing. The recess may include a geometry comprising a first width at the surface and a second width at a depth within the recess, where the first width may be less than the second width. Further, the component may be formed by sintering. In a particular embodiment, the size of the recess may be reduced by 20-50% in all directions after sintering, and in some embodiments the member may be compression-loaded after sintering. 
     In some embodiments, the recess may have an undercut geometry, tapered geometry, or counterbored geometry. In additional embodiments, the geometry of the optical member may correspond to the geometry of the recess. The geometry of the optical member may be protruding or recessed with respect to the recess. In one embodiment, the optical member may include sapphire glass. In some embodiments, the optical member may include multiple segments, which may be sandwiched, and may optionally include a transparent member between the segments, for example one or more of an optical or visual material. The optical member may include or be used in one or more of a window, control, or display. In additional embodiments, the housing may include multiple segments. The inner surface of the recess on the housing may also include a visual material. 
     The methods may also include tuning the remaining gap between the recess and the optical member after sintering or cooling, and may include disposing an adhesive, chemical bonding agent, or sealant between the recess and optical member. In some embodiments, the adhesive, chemical bonding agent, or sealant may be zirconia or ceramic slurry. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The described embodiments will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1A  shows an illustrative perspective view of a portion of a ceramic housing having a recess formed within a surface, according to embodiments. 
         FIG. 1B  shows an illustrative perspective view of the geometry of the recess formed within the surface of the ceramic housing of  FIG. 1A , according to embodiments. 
         FIG. 2A  shows an illustrative front view of an optical member, according to embodiments. 
         FIG. 2B  shows an illustrative plane view of an optical member, according to embodiments. 
         FIG. 3A  shows an illustrative front cross-sectional view of an interlocking ceramic housing and an optical member before performing a sintering process, according to embodiments. 
         FIG. 3B  shows an illustrative plane perspective view of the interlocking ceramic housing and optical member of  FIG. 3A  before performing a sintering process, according to embodiments. 
         FIG. 3C  shows an illustrative front cross-sectional view of the interlocking ceramic housing and the optical member of  FIG. 3A  after performing a sintering process, according to embodiments. 
         FIG. 3D  shows an illustrative plane perspective view of the interlocking ceramic housing and the optical member of  FIG. 3A  after performing a sintering process, according to embodiments. 
         FIG. 4A  shows an illustrative front cross-sectional view of an interlocking ceramic housing and an optical member before performing a sintering process, according to additional embodiments. 
         FIG. 4B  shows an illustrative front cross-sectional view of the interlocking ceramic housing and the optical member of  FIG. 4A  after performing a sintering process, according to additional embodiments. 
         FIG. 4C  shows an illustrative front cross-sectional view of the interlocking ceramic housing and the optical member of  FIG. 3A  including a bonding agent, according to additional embodiments. 
         FIG. 5A  shows an illustrative front cross-sectional view of an interlocking ceramic housing having an ink coating and an optical member before performing a sintering process, according to another embodiment. 
         FIG. 5B  shows an illustrative front cross-sectional view of the interlocking ceramic housing having an ink coating and the optical member of  FIG. 5A  after performing a sintering process, according to another embodiment. 
         FIG. 6  is a flow chart illustrating a method of manufacturing an interlocking ceramic and an optical member, according to embodiments. 
         FIG. 7A  is an illustrative front perspective view of an electronic device incorporating an interlocking ceramic and an optical member according to embodiments. 
         FIG. 7B  is an illustrative back perspective view of the electronic device incorporating the interlocking ceramic and the optical member of  FIG. 7A , according to embodiments. 
         FIGS. 8A-8C  are illustrative front cross-sectional views of an interlocking ceramic housing and the optical member of  FIG. 2A  undergoing assembly processes, according to further embodiments. 
         FIGS. 9A-9C  are illustrative front cross-sectional views of a two-part interlocking ceramic housing and an optical member undergoing assembly processes, according to additional embodiments. 
         FIGS. 10A and 10B  are illustrative front cross-sectional views of a two-part interlocking ceramic housing and a two-part optical member undergoing assembly processes, according to an additional embodiment. 
         FIG. 11  is an illustrative front cross-sectional view of an interlocking ceramic housing and a two-part optical member including an extended portion, according to embodiments. 
         FIGS. 12 and 13  are illustrative front cross-sectional views of an interlocking ceramic housing, and optical member and a retention member, according to embodiments. 
     
    
    
     It is noted that the drawings of the invention are not necessarily to scale. The drawings are intended to depict only typical aspects of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings. 
     DETAILED DESCRIPTION 
     The following detailed description relates generally to ceramic components, more particularly to interlocking ceramic and optical members, and methods of their manufacture. Numerous specific details are set forth to provide a thorough understanding of the concepts underlying the embodiment described herein and in the figures. However, the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, this application contemplates alternatives, modifications, and equivalents as can be included within the spirit and scope of the described and illustrated embodiments as defined by the appended claims. Embodiments are discussed below with reference to the Figures. 
       FIG. 1A  is a perspective view of a portion of a ceramic housing  100  in accordance with an embodiment. The housing  100  may be of any shape, and is shown in its simplest form as a planar sheet having a vertical thickness. In some embodiments, the housing  100  can be the housing of an electronic device, including but not limited to a cellular phone, tablet device, media device, or personal computer. The housing  100  may be integrated into a larger device, or may itself substantially define the shape and form of the device. 
     During the manufacture of the final part, the housing  100  may be formed using green-state ceramic materials (also herein referred to as “green body”), which may include a variety of ceramic materials that has not been fully heat treated or cured. In some cases, the green body retains the ability to undergo expansion upon heating or sintering. In non-limiting examples, ceramics may include both clay and non-clay inorganic materials, and both oxides and non-oxides, as understood in the art. In typical embodiments, ceramics include one or more of alumina, zirconia, carbides, borites, nitrides, and silicides. Production of ceramics typically involve creating a material powder, shaping a green body, and then heating or firing (“sintering”) the composition at 1600° C. to 1800° C. 
     The housing  100  may be created by any process or method of shaping ceramic, as understood in the art. For example, in some embodiments the housing  100  is cast in shape from a ceramic-based slurry mixture. In other embodiments, the housing  100  is removed, cut, or milled from a larger piece. The ceramic material selected generally depends on many factors including, but not limited to, strength (tensile), density (light weight), strength to weight ratio, Young&#39;s modulus, corrosion resistance, formability, finishing, recyclability, tooling costs, electrical and/or thermal conductivity, radio wave transparency, and aesthetic qualities. In a non-limiting example, the ceramic may include zirconia, which may provide adequate RF transmission, as well as environmental protection for internal electrical components. In some embodiments, the housing  100  may be multiple layers or sheets, and may optionally include additional materials and components. The housing  100  may also be of any thickness, which will vary depending on the use of the final composition. 
     As shown in  FIG. 1A , the housing  100  includes a recess  102  formed within a surface. The recess  102  may be of any suitable size, which is determined by the specific application. In a non-limiting example, a relatively small recess  102  on a surface  108  may be utilized for a camera system in an electronic device (see,  FIGS. 7A and 7B ); while a relatively large recess  102  on the surface  108  may be utilized for a protective cover for a display of the electronic device. A “surface,” as used herein, may be any suitable structure or housing formed from any suitable material including, but not limited to, glass, ceramic (of which sapphire, zirconia and alumina are examples), metal, wood, plastic and other polymers, and so on. 
     The recess  102 , when viewed from above, may be of any shape depending on the application, and may include but is not limited to a circle, square, or rectangle. In some embodiments, the recess  102  may pass completely through the housing  100 , or may pass through multiple separate or integrated sheets, such as through layered ceramic compositions or the hollow housing of an electronic device (see,  FIG. 7A  and  FIG. 7B ). In other embodiments, the recess  102  may not pass completely through the housing, and may be formed such that some material is left around at least the bottom or top of the recess. 
     As shown in  FIGS. 1A and 1B , the recess  102  has geometry  104 , which comprises a first width (W 11 ) at the surface  108  and a second width (W 12 ) at a depth  106  within the recess  102 . The first width (W 11 ) may be greater than the second width (W 12 ). The geometry  104  is configured to provide a mechanical interlock with an optical member (see,  FIGS. 3A-3D ) after the ceramic material of the housing undergoes heat expansion. The geometry  104  may be created by any suitable process, including but not limited to casting or milling. Non-limiting examples for geometry  104  may include an undercut geometry, tapered geometry, or counterbored geometry. “Undercut” as used herein may refer to the profile shape of an object where at least one diameter or dimension perpendicular to and along a vertical axis of a recess is smaller than the largest diameter or dimension of one or both of the vertical axis endpoints located at an end of the recess, as understood in the art. Objects with an undercut geometry may appear to have material removed, such as a reduction in the middle diameter of a 3D object such as a cube or cylinder. “Tapered” as used herein may refer to the profile shape of an object where at least one diameter or dimension perpendicular to the vertical axis is larger than the diameter or dimension of one of the vertical endpoints. A tapered geometry may also refer to the profile geometry of an object capable of interlocking with an object having undercut geometry. “Counterbored” may refer to a geometry in which one of the vertical endpoints is significantly larger in diameter than a nearby vertical point, and may refer to a recess that is formed using a counterboring process. In some cases, counterbored be referred to interchangeably with tapering. 
     “Interlocking” as used herein may refer to the property of two or more objects that physically engage each other or fit together due to their geometry, i.e. corresponding projections and recesses. In some cases, interlocking components or members are retained in place by a mechanical engagement or overlap between the two pieces. It is envisioned that various geometric configurations may result in interlocking, and that all are within the scope of the invention. In non-limiting examples, interlocking geometry may incorporate various features, such as but not limited to hooking or dovetailing. In some embodiments, interlocking results in enhanced resistance to mechanical forces from one or more directions, increasing the strength of a composition incorporating multiple objects. 
     Because a ceramic material may have a higher coefficient of thermal expansion, as compared to other materials typically incorporated into ceramic housings (such as, windows and electronics), a sintering process may be used to retain a component or member within a ceramic material. For example, an object having a thermal expansion that is less than the ceramic material can be placed into a recess in the ceramic housing  100  and be retained in the recess after the housing  100  is heated. In some cases, heat expansion of the ceramic forming housing  100  will reduce the size of recess  102 , and/or substantially expand the size housing  100 . In some examples, recess  102  may be reduced in size by 20-45% in both diameter and thickness. This technique has the advantage of relying on the geometric configuration of two or more high-strength objects to keep a material in place, increasing the overall strength of the composition to at least around that of the other object, instead of including an undesirable bezel. 
     A non-limiting example of the geometry  104  is provided in  FIGS. 1A and 1B , showing recess  102  as tapered or hour glass shaped. However, geometry  104  may include any profile where at least one point of recess  102  has a smaller diameter or width (e.g., second width W 12 ) than an endpoint width (e.g., first width W 11 ). In some embodiments, there may be additional materials around at least one of the vertical endpoints, such as where the recess  102  does not pass completely through the housing  100 , as discussed above. 
     The composition may also have additional visual materials or treatments along the inner surface or depth  106  of the recess  102 . In some examples, a visual material or treatment may provide a desired visual appearance of a device by, for example, incorporating a design, pattern, color, or light element. Visual materials or treatments may also have functional properties. In some embodiments, the visual materials or treatments include a color or pattern that is applied to the recess when the material is in a green state. The visual material or treatment may include any suitable material such as a metal anodized material or dye, or may be formed using an etching or patterning process. In some embodiments, the visual materials include adhesives or other binding agents applied before or after sintering, and may have additional functionality, such as strengthening the product. 
       FIGS. 2A and 2B  show a front and top view, respectively, of an optical member  200 . Optical members  200  are useful to transmit light to or from the housing  100 , as the housing  100  is generally made from ceramic and does not transmit light through its surfaces. In some embodiments, the optical member  200  is a translucent, transparent, or optically clear material, such as sapphire glass, however it may be made from any light transmitting material. Exemplary optical materials and optical members  200  are objects and devices having the property of transforming, reshaping, or altering the direction or path of a light input. In some embodiments, optical devices may transform a light input into an electrical image. The devices may be part of or comprise a larger functional unit, such as but not limited to a window, control, or display. Some materials may be optically clear, having the property of transmitting one or more wavelengths of light without significantly transforming, reshaping, or altering its direction or path. 
     Non-limiting examples of optically clear materials may include glass, e.g., sapphire, and optically clear adhesives. Because sintering may require local temperatures in excess of 1400° C., the optical member  200  may incorporate materials that can withstand high temperatures, (e.g., sapphire glass). In some embodiments, the optical member  200  may have a lower coefficient of thermal expansion than the housing  100 . Sapphire glass is an exemplary material providing high light transmission, durability, and minimal thermal expansion in optical members  200 . 
     As shown in  FIG. 2 , the optical member  200  has geometry  202 , which may facilitate interlocking with recess  102  on housing  100  (see,  FIG. 1A ) after sintering. In some embodiments, the geometry may substantially correspond with that of recess  102 , and may have tapered geometry or undercut geometry. As discussed herein, the optical member  200  may be smaller or larger than the final sintered geometry of the housing  100 , resulting in a protruding or recessed optical member  200  along the surface  108  of the housing  100 . As shown in  FIG. 2A , the optical member  200  comprises multiple joined members  204   a ,  204   b . More specifically, optical member  200  may be formed from distinct joined members  204   a ,  204   b . As shown in  FIGS. 2A and 3A , joined members  204   a ,  204   b  may be joined at a surface  205  prior to further processing involving optical member  200 . Joined members  204   a ,  204   b  may be joined at a surface  205  using any suitable joining technique or component including, but not limited to, a bonding agent, welding the edges, melting and the like, as discussed herein. In another non-limiting embodiment, and as discussed herein with respect to  FIGS. 8A-8C , joined members  204   a ,  204   b  may be joined after positioning one of the joined members  204   a ,  204   b  within housing  100 . This design allows additional optical or visual materials to be placed between sandwiched layers of the optical material, e.g., sapphire, enhancing the function and aesthetic design of the composition. 
     Additionally, and as discussed herein, optical member  200  may include geometry  202  corresponding to the geometry  104  of housing  100 . As shown in  FIGS. 2A and 2B , optical member  200  includes a first width (W 21 ) and a second width (W 22 ). Similar to geometry  104  of recess  102  of housing  100 , the first width (W 21 ) of geometry  202  of optical member  200  may be less than the second width (W 22 ) of optical member  200 . 
       FIG. 3A  provides an illustrative front cross-sectional view of the interlocking ceramic housing  100  and optical member  200  before sintering, e.g., in a green state.  FIG. 3B  shows an illustrative top view of the same in  FIG. 3A  before sintering. The geometry  104  of the housing  100  and the geometry  202  of optical member  200  allows optical member  200  to be disposed  300  into recess  102 . That is, optical member  200  may be smaller in size than recess  102  of housing  100 , such that optical member  200  may be disposed and/or positioned directly within recess  102  prior to sintering housing  100 . Additionally, as shown in  FIG. 3A , and as discussed herein, geometry  202  of optical member  200  may correspond to geometry  104  of housing  100 . That is, geometry  202  of optical member  200  may be correlative and/or may substantially match geometry  104  of recess  102 . 
       FIG. 3C  shows an illustrative front cross-sectional view after sintering, and  FIG. 3D  shows an illustrative top view after sintering, according to embodiments. In this example, the housing  100  undergoes more heat expansion than optical member  200  during a sintering process, resulting in interlocking housing  100  with the optical member  200 . In some implementations, during the sintering process, housing  100  and optical member  200  may both undergo heat expansion and increase in size. Specifically, as shown in  FIGS. 3C and 3D , housing  100  may increase in size and may ultimately reduce the size of recess  102 . Additionally, optical member  200  may also increase in size and substantially fill the reduced size of recess  102 . As a result of the specific coefficient of thermal expansion for each material forming housing  100  and optical member  200 , respectively, the expansion of each component may vary. In this particular example, the material forming housing  100  may have a higher coefficient of thermal expansion than the material forming optical member  200 . As a result of the specific and distinct coefficients of thermal expansions, and as shown in  FIGS. 3C and 3D , the expansion of size in housing  100  (e.g., reduction in size of recess  102 ) may be greater than the expansion of size in optical member  200 . 
       FIGS. 4A and 4B  show a front cross-sectional view of the interlocking ceramic housing  100  and optical member  200  before sintering and after sintering, respectively. The sintering process performed on ceramic housing  100  and optical member  200  may be substantially similar to the sintering process discussed herein with respect to  FIGS. 3A-3D . However, distinct from  FIGS. 3A-3D , housing  100  and optical member  200  may include tapered geometries. It is understood that similarly named components or similarly numbered components may function in a substantially similar fashion, may include similar materials and/or may include similar interactions with other components. Redundant explanation of these components has been omitted for clarity. 
     As shown in  FIG. 4B , subsequent to the sintering process, optical member  200  may extend beyond surface  108  of housing  100 . That is, a portion of optical member  200  may expand about surface  108  and out of recess  102  of housing  100  as a result of sintering housing  100  and optical member  200 . By extending above surface  108  of housing  100 , optical member  200  may require further processing to make optical member  200  aligned with surface  108 . Additionally, optical member  200  extending above surface  108  may more clearly define optical member  200  within housing  100  to a user. For example, a user touching housing  100  including optical member  200  may more clearly, and distinctly feel optical member  200  as a result of a portion of the optical member  200  extending above surface  108  of housing  100 . 
     Additionally as shown in  FIG. 4B , a space or gap  210  may exist between housing  100  and optical member  200  after a sintering process is performed. That is, and with comparison to  FIG. 3C , optical member  200  may expand as a result of the sintering process, but may not completely fill at least a portion of reduced recess  102  of housing  100 . As such, gap  210  may be formed with in recess  102  between housing  100  and optical member  200 . Additionally, as shown in  FIG. 4B , a portion of optical member  200  may substantially fill a portion of recess  102  of housing  100 , which may have an interlocking or coupling affect between the portion of optical member  200  and housing  100 . 
     Turning to  FIG. 4C , a front cross-sectional view of the interlocking ceramic housing  100  and optical member  200  is shown after sintering, similar to  FIG. 4B . However, as shown in  FIG. 4C , gap  210  formed between housing  100  and optical member  200  may be substantially filled with bonding agent  212 . Specifically, gap  210  may be filled with the bonding agent  212  to complete the interlocking between housing  100  and optical member  200  after a sintering process is performed on the like. The bonding agent  212  may include an adhesive, a chemical bonding agent or any suitable sealant that may be disposed within gap  210 . In a non-limiting example, bonding agent  212  may include an adhesive formed from zirconia slurry that may be disposed in gap  210 , and subsequently cured to interlock optical member  200  to housing  100  where gap  210  exists between the respective components. 
       FIGS. 5A and 5B  show a front cross-sectional view of the interlocking ceramic housing  100  and optical member  200  before sintering and after sintering, respectively. Compared to  FIGS. 3A-4C , housing  100  and optical member  200  may include another distinct geometry. Specifically, housing  100  and optical member  200  may include a counterbored geometry. 
     Additionally, as shown in  FIGS. 5A and 5B , housing  100  may include an ink  218 . More specifically, housing  100  may include an ink  218  disposed over the inner surface of recess  102 . As shown in  FIGS. 5A and 5B , ink  218  may remain within recess  102  of housing  100  through the sintering process. That is, as the sintering process is performed on the housing  100  and optical member  200 , ink  218  may remain on the surface of recess  102  of housing  100 . Ink  218  may be a decorative ink for providing a visually appealing color, image and/or border of recess  102  and/or optical member  200  to a user. Additionally, ink  218  may include a reflective ink that may reflect light emitted through optical member  200 , as discussed herein. 
     Also shown in  FIG. 5B , optical member  200  may be formed below surface  108  of housing  100 . That is, and opposite optical member  200  discussed in  FIG. 4B , a sintering process performed on housing  100  and optical member  200  may result in optical member  200  including a portion positioned below surface  108  of housing  100 . However, similar to the effects discussed herein with respect to  FIG. 4B , optical member  200  positioned below surface  108 , as shown in  FIG. 5B , may provide a tactile and/or visual indicator to the user of optical member  200  positioned in housing  100 . 
       FIG. 6  is a flow chart illustrating a method of manufacturing an interlocking ceramic and optical member, according to embodiments. In operation  402 , an optical member  200  having geometry  202  may be disposed into recess  102  of a first member (ceramic housing  100 ). Once disposed into recess  102 , the first member may be sintered in operation  404 . The sintering may result in heat expansion of the ceramic and reduction in the size of the recess  102 . Reduction in the size of recess  102  results in the interlocking of the first member (housing  100 ) and member  200  due to their respective geometries  104  and  202 . In optional operation  406  (shown in phantom), the remaining gap between recess  102  and member  200  may be tuned. Tuning may be performed by additional heat application, or may involve the use of adhesives or binding agents, as discussed above. The first member is then cooled in operation  408 , resulting in an interlocking composition. In an additional, optional operation  410  (shown in phantom), subsequent tuning may be performed at this time on the first member (housing  100 ) and optical member  200 . 
       FIG. 7A  is an illustrative perspective view of an electronic device  700  incorporating an interlocking ceramic and optical member according to embodiments.  FIG. 7B  is an illustrative back perspective view of an electronic device  700  incorporating an interlocking ceramic and optical member according to embodiments. Due to the properties and characteristics of ceramic, ceramic components are highly useful in the construction of portable electronic devices. Modern portable electronic devices, for example laptop computers, tablet computers, PDAs, media players, cellular phones, and smart phones, are often be light weight, durable, and capable of wireless communication. Ceramic components are useful, for example, as a casing for these devices, and can hold and protect the delicate internal electronics while presenting a comfortable and aesthetically pleasing exterior. However, device screens, touch-sensitive buttons and controls, cameras, and other optical inputs often require the use of non-ceramic other materials to achieve the desired functionality and protection. 
     Typically, the electronic device  700  comprises one or more of a housing  702 , display  708 , cover glass  710 , input button  704 , data and/or power connector  712 , audio jack or other port  714 , front facing camera  706 , rear facing camera  716 , power switch  718 , and volume control  720 . 
     In embodiments, the housing  702  may include a ceramic. One or more of the display  708 , cameras  706  and  716 , input interfaces  704 ,  718  and  720 , and component inputs  712  and  714  may comprise an optical member  200  (see,  FIGS. 2A-3D ) requiring a recess in the housing  702  formed from ceramic. One or more of these recesses may be a recess  102  as described above, having geometry  104 , and one or more of the optical members  200  may have geometry  202 . Interlocking the housing  702  and optical member  200  forming various components of the electronic device  700  (e.g., display  708 , cameras  706  and  716 ) according to the methods above has the benefits of providing a desirable bond and aesthetically pleasing design. The electronic device  700  retains the desirable material properties of the ceramic housing, but still allows optical communication to and from a user of said electronic device  700 . Additionally, large bezels are not required, allowing larger screens and input devices relative to a surface are of the electronic device  700 . The electronic device  700  may also be substantially seamless, improving the water resistance, durability, longevity, and cleanliness of the electronic device  700 . Even further, the aesthetic appeal and tactile feel of the electronic device  700  are improved by removing protrusions from the housing  702 . 
       FIGS. 8A-8C  depict illustrative cross-section views of the optical member  200  being positioned within a distinct housing  800 . More specifically,  FIGS. 8A-8C  depict optical member  200  including joined members  204   a ,  204   b , as discussed herein with respect to  FIG. 2A , positioned, coupled and/or fixed within housing  800 . 
     As shown in  FIG. 8A , housing  800  may include a housing substantially similar to that of the housing  100  discussed herein with respect to  FIGS. 1A and 3A-3D . That is, housing  800  may be formed from a ceramic material and may be formed as a single body. However, housing  800  may be distinct from housing  100  in that housing  800  may be substantially fixed in its shape. More specifically, housing  800  may include recess  802  that may include a fixed or preformed geometry  804  that may not be altered or changed during subsequent processing on housing  800 . 
     A portion of optical member  200  may be initially positioned within housing  800 . More specifically, as shown in  FIG. 8A , joined member  204   a  of optical member  200  may initially be positioned within a lower portion  850  of recess  802  of housing  800 . As shown in  FIG. 8A , joined member  204   a  may include a geometry substantially similar to the geometry  804  of recess  802  formed in the lower portion  850  of housing  800 . Joined member  204   a  may be positioned within housing  800 , and may also be coupled within housing  800  using a compression fit, as shown in  FIG. 8A . In another non-limiting embodiment, joined member  204   a  initially positioned within recess  802  of housing  800  may be coupled to housing  800  using an adhesive or bonding agent  212  (see,  FIG. 8C ). 
     Once joined member  204   a  is positioned within recess  802  of housing  800 , joined member  204   b  of optical member  200  may be positioned within housing  800 . That is, and as shown in  FIG. 8B , joined member  204   b  may be positioned within an upper portion  852  of recess  802  of housing  800  subsequent to the joined member  204   a  being positioned within lower portion  850 . As shown in  FIG. 8B , and as similarly discussed herein with respect to joined member  204   a , joined member  204   b  may also be coupled to housing  800  using a compression fit and/or an adhesive bonding agent  212  (see.  FIG. 8C ). 
     Additionally as shown in  FIG. 8B , joined member  204   b  positioned in upper portion  852  of housing  800  may contact and/or be coupled to joined member  204   a  formed in lower portion  850 . Joined member  204   b  may be coupled to joined member  204   a  to form optical component  200 , as discussed herein with respect to  FIG. 2A . As shown in  FIG. 8B , joined member  204   b  may be coupled to joined member  204   a  using an optically transparent adhesive  254 . Optically transparent adhesive  254  may be formed around the edges of contacting joined members  204   a ,  204   b , or may be formed on the entire contacting or mating surface of joined members  204   a ,  204   b . Additionally, and as discussed herein, transparent bonding agent  212  may include aesthetics, such as a texture or a visual component (e.g., a logo), formed therein, such that the aesthetics may be visible through joined member  204   b  of optical component  200 . 
       FIG. 8C  depicts formed optical member  200  positioned within and coupled to housing  800 . As shown in  FIG. 8C , and discussed herein, joined components  204   a ,  204   b  may be coupled to housing  800  using bonding agent  212 . In a non-limiting example, bonding agent  212  may be flowed through housing  800  after joined members  204   a ,  204   b  are positioned within housing  800  and coupled to each other to form optical member  200 . In the example, bonding agent  212  may settle in any gaps or spaces that may exist between optical component  200  and housing  800  for bonding optical component  200  to housing  800 , as similarly discussed herein with respect to  FIG. 4C . In another non-limiting example, as briefly discussed above, bonding agent  212  may be formed within recess  802  of housing  800  prior to positioning joined member  204   a  in lower portion  850 , and/or positioning joined member  204   b  in upper portion  852 . Additionally, and as discussed herein, as a result of the geometries of both the housing  800  and optical component  200 , optical component  200  may be positioned within housing  800  and may not be removed. 
       FIGS. 9A-9C  depict illustrative cross-section views of the optical member  200  being positioned within another housing  900 . More specifically,  FIGS. 9A-9C  depict optical member  200  coupled and/or fixed within housing  900  including a lower portion  950  and an upper portion  952 . 
       FIG. 9A  shows housing  900  including two distinct portions. Specifically,  FIG. 9  depicts housing  900  including a lower portion  950  and an upper portion  952 . Each of the lower portion  950  and upper portion  952  include a portion of recess  902  including a geometry  904 . When coupled together, lower portion  950  and upper portion  952  may form recess  902  of housing  900  including a geometry  904  that may correspond to a geometry of optical member  200 . 
       FIG. 9B  shows optical member  200  positioned within recess  902  of lower portion  950  of housing  900 . That is, single body optical member  200  may be positioned within and/or coupled to lower portion  950  of housing  900 , as similarly discussed herein. Additionally, as shown in  FIG. 9B , upper portion  952  of housing  900  may be aligned within lower portion  950 . Specifically, upper portion  952  may be positioned above lower portion  950  and may align recess  902  of upper portion  952  with optical member  200  for subsequent coupling of upper portion  952  to lower portion  950  and/or optical component  200 . As shown in  FIG. 9B , lower portion  950  may also include bonding agent  212  positioned on a contact surface surrounding optical member  200 . As discussed herein, bonding agent  212  may be used to couple upper portion  952  to lower portion  950  to forming housing  900 . 
       FIG. 9C  shows upper portion  952  of housing  900  contacting lower portion  950  of housing  900 . More specifically, upper portion  952  may be coupled to lower portion  950  to form a complete housing  900 . As shown in  FIG. 9C , upper portion  952  of housing  900  may be coupled to lower portion  950  using bonding agent  212  formed between upper portion  952  and lower portion  950 . Additionally, as shown in  FIG. 9C , upper portion  952  of housing  900  may be coupled to optical member  200 . 
       FIGS. 10A and 10B  depict illustrative cross-section views of the optical member  200  being positioned within another housing  900  according to distinct embodiments. As shown in  FIGS. 10A and 10B , optical component  200  may be formed from joined members  204   a ,  204   b.    
     In an initial process, as shown in  FIG. 10A , joined member  204   a  may be positioned within and/or coupled to lower portion  950  of housing  900 . Joined member  204   a  may be coupled to lower portion  950  using bonding agent  212 , as discussed herein. Additionally, as shown in  FIG. 10A , joined member  204   b  of optical member  200  may be positioned within and/or coupled to upper portion  952  of housing  900  in a similarly fashion as joined member  204   a  in lower portion  950  (e.g., bonding agent  212 , compression fit). 
     As shown in  FIG. 10B , upper portion  952  of housing  900 , including joined member  204   b , may contact and/or be coupled to lower portion  950  including joined member  204   a . As shown in  FIG. 10B , and discussed herein with respect to  FIG. 9C , upper portion  952  may be coupled to lower portion  950  using bonding agent  212  to form housing  900 . Additionally as shown in  FIG. 10B , and as similarly discussed herein with respect to  FIGS. 8B and 8C , joined member  204   b  may be coupled to joined member  204   a  using optically transparent adhesive  254  to form optical member  200 . 
     Although it is shown to position joined members  204   a ,  204   b  within the respective portions of housing  900  prior to the coupling of the portions of housing  900  and/or the coupling of joined members  204   a ,  204   b , it is understood that distinct steps may be taken to form optical component  200  within housing  900 . In another non-limiting example not shown, joined members  204   a ,  204   b  may be coupled to form optical component  200  prior to upper portion  952  being coupled to lower portion  950  to form housing  900 . That is, joined member  204   b  may be coupled to joined member  204   a  to form optical member  200  within lower portion  950  of housing  900 . This process may be similar to the process discussed herein with respect to  FIGS. 9B and 9C . Once optical member  200  is formed from coupling joined members  204   a ,  204   b , upper portion  952  may be subsequently coupled to lower portion  950  to form housing  900 . 
       FIGS. 11-13  depict additional embodiments used for securing optical component  200  within housing  1000 . Specifically, as shown in  FIGS. 11-13 , housing  1000  may be substantially thin and/or may not include a reduced thickness. As such, housing  1000  may be more fragile than a thicker housing (see, housing  100 ). Additionally, because housing  1000  includes a substantially reduced thickness, there may be less area to bond optical component  200  within recess  10002  of housing  1000 . 
     As shown in  FIG. 11 , optical component  200  may be formed from joined members  204   a ,  204   b , as similarly discussed herein. Joined members  204   a ,  204   b  may be fixed to one another using optically transparent adhesive  254 , and may be coupled to housing  1000  using bonding agent  212 . Additionally as shown in  FIG. 11 , joined member  204   a  extend from housing  1000 . Specifically, joined member  204   a  may be designed to be oversized and/or longer than the portion of housing  1000  for which joined member  204   a  is coupled. The portion of joined member  204   a  may extend beyond housing  1000  to provide additional retention of joined member  204   b  and ultimately optical member  200  within housing  1000 . That is, the portion of joined member  204   a  that may be larger than recess  1002  in housing  1000  may prevent optical component  200  from being removed form recess  1002  because of the differences in geometry between joined member  204   a  and recess  1002  of housing  100 . 
       FIGS. 12 and 13  show the inclusion of a retention member  256  used to coupled optical member  200  within housing  1000  and to prevent undesirable removal of optical member  200  from housing  1000 . Retention member  256  may be coupled to optical member  200  using optically transparent adhesive  254 . Additionally, as shown in  FIGS. 12 and 13 , retention member  256  may also be coupled to a portion of housing  1000 . In non-limiting examples, retention member  256  may be coupled to housing  1000  using optically transparent adhesive  254 , as shown in  FIGS. 12 and 13 , or may be coupled to housing  1000  using bonding agent  212 . As shown in  FIGS. 12 and 13 , retention member  256  may be substantially larger than recess  10002  of housing  1000  to prevent optical member from being removed from housing  1000  and/or to aid in the coupling of optical member  200  within housing  1000 . As shown in  FIG. 12 , retention member  256  may be substantially centered on optical member  200 . Distinctly, as shown in  FIG. 13 , retention member  256  may be substantially off-center when coupled to optical member  200  where a distinct internal component  258  may be positioned adjacent optical component  200 . Retention member  256  may still provide the desired bonding and/or removal prevention to optical component  200  when off-center, so long as a portion of retention member  256  is coupled completely around or adjacent to recess  10002  of housing  1000 . 
     As described above, in some embodiments, an optical member is disposed in a recess that is formed in a housing or ceramic member. In some embodiments, the recess may be formed in a clear member, including, for example, the cover glass, sapphire component or other optically transparent material. In some case, the recess may be formed in a member which may refer generically to a housing, ceramic member, cover glass, sapphire part, or other type of component. 
     While the invention has been particularly shown and described with reference to a number of embodiments, it would be understood by those skilled in the art that changes in the form and details may be made to the various embodiments disclosed herein without departing from the spirit and scope of the invention and that the various embodiments disclosed herein are not intended to act as limitations on the scope of the claims. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20140828
Publication Date: 20190205
Grant Date: 20190205
Priority Date: 20140828
Inventors: NAZZARO, DAVID I.
MATSUYUKI, NAOTO
MOLINA, RAUL A.
ROTHKOPF, FLETCHER R.
HAN, Chin San
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/0264", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/0264", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 54818710