PATENT DOCUMENT

Publication Number: US-10606218-B1
Application Number: US-201816141885-A
Country: US
Kind Code: B1

Title: Ceramic weave for low-cost, structural, antenna-permeable watch case

Abstract:
A composite housing of an electronic device can include a substrate having a shape that partially defines an internal volume of the electronic device and includes ceramic fibers arranged in a weave pattern and embedded in a matrix material. The composite housing can also include an overmold material at least partially surrounding the substrate and an antenna integrated into the overmold material.

Claims:
What is claimed is: 
     
       1. A housing of an electronic device, comprising:
 a substrate partially defining an internal volume of the electronic device and including ceramic fibers arranged in a weave pattern and embedded in a matrix material; 
 an overmold material at least partially surrounding the substrate and at least partially defining an exterior surface of the electronic device; and 
 an operational component integrated into the overmold material and positioned between the substrate and the exterior surface. 
 
     
     
       2. The housing of  claim 1 , further comprising:
 an aperture passing through the substrate and the overmold material; 
 a transparent element positioned within the aperture; and
 the overmold material including an attachment feature. 
 
 
     
     
       3. The housing of  claim 1 , wherein the operational component comprises an antenna. 
     
     
       4. The housing of  claim 3 , wherein the substrate amplifies a signal transmitted by the antenna. 
     
     
       5. The housing of  claim 1 , wherein the ceramic fibers comprise zirconia or alumina. 
     
     
       6. The housing of  claim 1 , wherein the matrix material comprises a thermoset polymer, thermoplastic polymer, or combinations thereof. 
     
     
       7. The housing of  claim 1 , wherein the overmold material comprises a polymer. 
     
     
       8. The housing of  claim 1 , wherein the weave pattern comprises a fabric weave pattern. 
     
     
       9. The housing of  claim 8 , wherein the weave pattern comprises a satin weave. 
     
     
       10. A component of an electronic device, comprising:
 a substrate including a ceramic material; 
 an overmold material at least partially surrounding the substrate and at least partially defining an exterior surface of the electronic device; and 
 an operational component at least partially surrounded by the overmold material, the operational component positioned between the substrate and the exterior surface. 
 
     
     
       11. The component of  claim 10 , wherein the substrate comprises ceramic fibers embedded in a matrix material. 
     
     
       12. The component of  claim 11 , wherein the ceramic fibers are arranged in a weave pattern. 
     
     
       13. The component of  claim 11 , wherein the ceramic fibers are substantially randomly oriented throughout the substrate. 
     
     
       14. The component of  claim 11 , wherein the matrix material comprises a thermoset polymer, thermoplastic polymer, or combinations thereof. 
     
     
       15. The component of  claim 10 , wherein the ceramic material comprises zirconia or alumina. 
     
     
       16. The component of  claim 10 , wherein the overmold material comprises a polymer. 
     
     
       17. A method of forming a component of an electronic device, comprising:
 solidifying a matrix material at least partially around ceramic fibers to form a substrate; 
 cutting the substrate into a desired shape; 
 disposing an operational component adjacent to the substrate; and 
 overmolding the substrate and the operational component with a moldable material so the moldable material at least partially surrounds the substrate and the operational component, the moldable material contacting the substrate and comprising a material different from the substrate. 
 
     
     
       18. The method of  claim 17 , wherein cutting the substrate comprises laser-cutting the substrate to form an aperture. 
     
     
       19. The method of  claim 17 , wherein the ceramic fibers are arranged in a weave pattern. 
     
     
       20. The method of  claim 17 , wherein the ceramic fibers are substantially randomly oriented throughout the matrix material.

Description:
FIELD 
     The described embodiments relate generally to composite articles for electronic devices. More particularly, the present embodiments relate to ceramic composite articles for electronic devices and methods of forming the same. 
     BACKGROUND 
     Electronic devices are widespread in society and can take a variety of forms, from wristwatches to computers. Electronic devices, including portable electronic devices such as handheld phones, tablet computers, and watches, can experience contact with various surfaces during use. Further, the use, transportation, and storage of such devices can exert mechanical and thermal stresses thereon. 
     Components for these devices, such as housings, can benefit from exhibiting different combinations of properties relating to the use of the device. A housing for a portable electronic device can have a combination of properties, such as strength, appearance, toughness, abrasion resistance, electromagnetic shielding, and cost, in order for the device to function as desired. Certain materials can provide a desired level of performance with respect to some properties, but not others. For example, a metal housing can be strong and tough, but can provide varying levels of electromagnetic shielding. A plastic housing can be electromagnetically transparent, but can have lower levels of strength, toughness, and abrasion resistance. Ceramic materials can be stronger than plastic, but can be more expensive to form and machine. 
     SUMMARY 
     One aspect of the present disclosure relates to a housing of an electronic device including a substrate having a shape partially defining an internal volume of the electronic device and including ceramic fibers arranged in a weave pattern. The weave pattern can be embedded in a matrix material. Additionally, an overmold material can at least partially surround the substrate. An operational component, such as an antenna, can be integrated into the overmold material. 
     In some embodiments, the housing can further include an aperture passing through the substrate and overmold material. A transparent element can be positioned within the aperture, and the overmold material can include an attachment feature to attach a component of the electronic device to the housing. The antenna can be a cellular antenna. The substrate can amplify a signal transmitted or received by the operational component, such as an antenna. The ceramic fibers can include zirconia or alumina. The matrix material can include a thermoset polymer, thermoplastic polymer, or combinations thereof. The overmold material can include a polymer. The weave pattern can be a fabric weave pattern. The weave pattern can be a satin weave pattern. 
     Another aspect of the present disclosure relates to a component of an electronic device including a substrate. The substrate can include a ceramic material, an overmold material at least partially surrounding the substrate, and an operational component, such as an antenna, at least partially surrounded by the overmold material. 
     In some embodiments, the ceramic material can include ceramic fibers, and the substrate can include the ceramic fibers embedded in a matrix material. The ceramic fibers can be arranged in a weave pattern. The ceramic fibers can be substantially randomly oriented throughout the substrate. The matrix material can include a thermoset polymer, thermoplastic polymer, or combinations thereof. The ceramic material can include zirconia or alumina. The overmold material can include a polymer. 
     Another aspect of the present disclosure relates to a method of forming a component of an electronic device, including solidifying a matrix material at least partially around ceramic fibers to form a substrate, cutting the substrate into a desired shape, disposing an antenna or other operational component adjacent to the substrate, and overmolding the substrate and the operational component with a moldable material so that the moldable material at least partially surrounds the substrate and the operational component. 
     In some embodiments, cutting the substrate can include laser-cutting the substrate to form an aperture therein. The ceramic fibers can be arranged in a weave pattern. The ceramic fibers can be substantially randomly oriented throughout the matrix material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure 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. 1  shows a perspective view of an electronic device. 
         FIG. 2  shows and exploded view of the electronic device of  FIG. 1 . 
         FIG. 3  shows a sectional view of an electronic device. 
         FIG. 4A  shows a perspective view of a component of an electronic device. 
         FIG. 4B  shows a top view of a component of the electronic device of  FIG. 4A . 
         FIG. 4C  shows a bottom view of a component of the electronic device of  FIG. 4A . 
         FIG. 4D  shows a side view of a component of the electronic device of  FIG. 4A . 
         FIG. 4E  shows a side view of a component of the electronic device of  FIG. 4A . 
         FIG. 4F  shows a front view of a component of the electronic device of  FIG. 4A . 
         FIG. 5A  shows a top view of a component of an electronic device. 
         FIG. 5B  shows a perspective cut-away view of a component of the electronic device of  FIG. 5A . 
         FIG. 5C  shows a sectional view of a component of the electronic device of  FIG. 5A . 
         FIG. 6A  shows a top schematic view of a component of an electronic device. 
         FIG. 6B  shows a top schematic view of a component of an electronic device. 
         FIG. 7A  shows a top view of a component of an electronic device. 
         FIG. 7B  shows a perspective cut-away view of a component of the electronic device of  FIG. 7A . 
         FIG. 7C  shows a sectional view of a component of the electronic device of  FIG. 7A . 
         FIG. 8A  shows a top view of a component of an electronic device. 
         FIG. 8B  shows a perspective cut-away view of a component of the electronic device of  FIG. 8A . 
         FIG. 8C  shows a sectional view of a component of the electronic device of  FIG. 8A . 
         FIG. 9A  shows an exploded view of an electronic device. 
         FIG. 9B  shows a sectional view of a component of the electronic device of  FIG. 9A . 
         FIG. 10A  shows an exploded view of an electronic device. 
         FIG. 10B  shows a sectional view of a component of the electronic device of  FIG. 10A . 
         FIG. 11  shows a process flow diagram of a process for forming a component of an electronic device. 
         FIG. 12  shows a process flow diagram of a process for forming a component of an electronic device. 
         FIG. 13  shows a process flow diagram of a process for forming a component of an electronic device. 
     
    
    
     DETAILED DESCRIPTION 
     The present description provides examples, and is not limiting of the scope, applicability, or configuration as set forth in the claims. Thus, it will be understood that changes can be made in the function and arrangement of elements discussed without departing from the spirit and scope of the disclosure, and various embodiments can omit, substitute, or add other procedures or components as appropriate. For instance, methods described can be performed in an order different from that described, and various steps can be added, omitted, or combined. Also, features described with respect to some embodiments can be combined in other embodiments. 
     One aspect of the present disclosure relates to composite components of electronic devices, such as, for example, all or a portion of a housing of an electronic device. The composite housing can include a substrate and an overmolded material at least partially surrounding the substrate. In some examples, an operational component, such as an antenna, can be integrated into or at least partially surrounded by the overmolded material. The antenna can transmit and/or receive wireless signals, for example, via a cellular network, Wi-Fi network, Bluetooth, and other similar wireless networks. 
     In some cases, the composite housing can allow wireless signals to be transmitted or received with less interference, attenuation, or shielding than if the housing were constructed entirely of a single material, such as a ceramic or metal material. In some cases, the composite housing, or a portion thereof, can amplify a wireless signal transmitted or received by the antenna. In some cases, the composite housing can have a high strength, toughness, and durability relative to a housing formed of a single material, such as a polymer. Further, the overmold material can provide a pleasing aesthetic appearance to the housing. 
     The substrate of the composite housing can include a ceramic material at least partially embedded in a matrix material. In some cases, the ceramic material can include ceramic fibers that can be arranged in a pattern, such as a weave pattern. A matrix material, such as a resin or epoxy, can partially, substantially, or entirely surround the ceramic fibers such that the ceramic fiber weave can be embedded in the matrix material. In some cases, the ceramic fibers can serve to amplify or reduce interference, attenuation, or shielding of wireless signals received or transmitted by the antenna. 
     A moldable material can be overmolded to at least partially surround the substrate. The overmold material can include any moldable material, such as a polymeric material. For example, the overmold material can include a polyamide material. Further, in some cases, the overmold material can include glass fibers embedded therein. The overmold material can be formed around the substrate such that the substrate and the overmold material form a single component. The overmold material can coat substantially an entire surface of the substrate defining an exterior portion of the housing, such that the overmold material forms an exterior portion of the housing. 
     The overmold material can have a higher durability and resistance to chemical attack than the substrate or a material forming the substrate. As such, the overmold material can provide for a housing with high durability and toughness, while the substrate can provide for a housing that has a very high strength. In this way, the substrate and the overmold material can cooperate to provide a housing with any number of desirable properties. Further, because the housing is not formed from a single material, such as a ceramic, the material and the processing costs of the housing can be greatly reduced relative to an entirely ceramic housing. 
     The materials and structures of the components, substrates, overmold materials, and antennas discussed herein can include any desired design or shape to serve any number of functions, or to provide any number of specifically tailored properties. The following discussion of composite components illustrates a variety of different embodiments and designs for use in electronic devices. Further, the materials, structures, and features discussed herein can be combined in any number or manner. 
     In some examples, the substrate can be designed to enhance a number of mechanical or other characteristics of a component, such as a housing. For example, the substrate can have a design that includes one or more ceramic structures that span the substrate in one or more directions. Such a structure can include a substantially solid ceramic component or ceramic fibers. In some cases, the ceramic fibers can be substantially randomly positioned throughout the substrate. In some other examples, however, the ceramic fibers can be arranged in a pattern, such as a weave. These ceramic structures can enhance the resistance of the component to bending or flexure, thereby providing a component that is much stronger and stiffer than, for example, a polymer housing. The ceramic material can include zirconia, alumina, or combinations thereof. 
     In some examples, the ceramic material is at least partially embedded in a matrix material. Thus, in some cases, the substrate can be a ceramic composite material. The matrix material can be a moldable or curable material, such as an epoxy or a resin. In some cases, the matrix material can include metallic material, amorphous materials such as glass, polymeric materials, or other compatible materials. The substrate can have a substantially uniform thickness, or in some cases, can vary in thickness along one or more dimensions. In some examples, the substrate can be from about 0.25 mm thick to about 1 mm thick, or even thicker. In some examples, the substrate can be about 0.5 mm thick. 
     The substrate can have any desired shape or design and, in some cases, can partially define an internal volume of an electronic device. In some examples, the substrate can include one or more apertures to allow one or more components of the electronic device to have visual or physical access to the environment exterior to the device. In some cases, a material, such as a visually transparent material, can have a peripheral shape corresponding to a shape of an aperture in the substrate and can be positioned therein. In some cases, the aperture and the transparent material can cooperate to allow for a component, such as a sensor, to detect one or more properties of the environment exterior to the electronic device. The transparent material can be a visually transparent material, such as sapphire or a transparent polymer. 
     The overmold material that, in some examples, can at least partially surround the substrate, can include any moldable material or combinations thereof. In some examples, the overmold material can be a metallic material, an amorphous material, or a polymeric material such as a polyamide. Further, in some cases, one or more additional materials can be included in the overmold material. For example, the overmold material can be a polyamide with glass fibers embedded therein. 
     In some cases, the overmold material can form or be an exterior surface of the component. Further, in some examples where the composite component is a housing of an electronic device, the overmold material can form or be an exterior surface of the electronic device. In some cases, the overmold material can have a thickness of from about 0.1 mm to about 0.5 mm, or from about 0.25 mm to about 0.45 mm. 
     An operational component, such as an antenna, can be integrated into or at least partially surrounded by the overmold material of the composite component. In some examples, the antenna can be substantially or entirely surrounded by the overmold material. In one example, one or more portions of the antenna configured to connect to or communicate with other components of the electronic device may protrude from or otherwise be exposed from the overmold material. 
     The antenna can include, or be formed from, a metal. In some cases, the antenna can include a substantially flat sheet of metal. In some other cases, however, the antenna can include any desired shape to receive and/or transmit wireless signals, such as signals of one or more desired frequencies. In some examples, the antenna can receive and/or transmit wireless signals at one or more frequencies, and can be, for example, one or more of a cellular antenna such as an LTE antenna, a Wi-Fi antenna, a Bluetooth antenna, a GPS antenna, a multi-frequency antenna, or another suitable antenna. The antenna can be communicatively coupled to one or more additional components of the electronic device. Further, in some cases, the ceramic material of the substrate can allow the antenna to transmit and/or receive wireless signals with less interference, attenuation, or shielding, than if the housing were constructed entirely of, for example, a metal material. In some cases, the substrate may amplify or otherwise enhance, for example, by reducing noise or increasing the amplification of, wireless signals received and/or transmitted by the antenna. 
     In some cases, the antenna can be integrated or otherwise incorporated into the overmold material during a forming process of the overmold material. For example, in some cases the antenna can be positioned relative to the substrate and the overmold material can be formed or solidified around the antenna and the substrate in a single step. In some other cases, a portion of the overmold material can be formed at least partially surrounding the substrate in a first stage, then the antenna can be positioned relative to the first portion of the overmold material while a second portion of the overmold material is formed in a second stage, resulting in the antenna being substantially or entirely surrounded by the overmold material. 
     Methods and processes for forming composite components are also provided herein. For example, a method of forming a composite component can include overmolding a substrate including a ceramic material and an operational component, such as an antenna, with a moldable material so that the moldable material at least partially surrounds the substrate and the operational component. In some cases, the method can further include forming the substrate including a ceramic material by solidifying a matrix material at least partially around ceramic fibers. The methods can further include cutting or otherwise shaping the substrate into a desired shape. For example, the substrate can be machined, etched, cut with a laser, or otherwise processed to achieve a desired shape. 
     Although one or more of these components and/or processes can be described in the context of handheld devices, such as mobile phones, laptops, and notebooks, the embodiments disclosed herein should not be interpreted or otherwise used as limiting the scope of the disclosure, including the claims. In addition, the following description has broad application. Accordingly, the discussion of any embodiment is meant only to be exemplary and is not intended to suggest that the scope of the disclosure, including the claims, is limited to these embodiments. 
     These and other embodiments are discussed below with reference to  FIGS. 1-13 . However, the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1  shows an embodiment of an electronic device  100 . The electronic device shown in  FIG. 1  is a watch, such as a smartwatch. The smartwatch of  FIG. 1  is merely one representative example of a device that can be used in conjunction with the systems and methods disclosed herein. Electronic device  100  can correspond to any form of wearable electronic device, a portable media player, a media storage device, a portable digital assistant (“PDA”), a tablet computer, a computer, a mobile communication device, a GPS unit, a remote control device, or other electronic device. The electronic device  100  can be referred to as an electronic device, or a consumer device. Further details of the electronic device are provided below with reference to  FIG. 2 . 
     Referring now to  FIG. 2 , the electronic device  100  can include a housing  101  and a cover  103  attached to the housing  101 . The housing  101  can substantially define at least a portion of an exterior surface of the device  100 . The cover  103  can include glass, plastic, or any other substantially transparent material, component, or assembly. The cover  103  can cover or otherwise overlay a display, a camera, a touch sensitive surface such as a touchscreen, or other component of the device  100 . The cover  103  can define a front exterior surface of the device  100 . Together, the housing  101  and the cover  103  can substantially define the exterior surface of the device  100 . 
     In some examples, the housing  101  can include a component  110  that defines at least an exterior surface of the device  100 . The component  110  can be referred to as a back case or a back cover, and in some cases, can be attached to one or more other components, such as frame  120 , to form the housing  101 . The component  110  can be attached to the frame  120  by any method known in the art or developed in the future, such as adhesive bonding, brazing, welding, overmolding, interference fitting, or other securing methods. In some cases, however, the component  110  can form or be the entire housing  101  of the electronic device  100 . The component  110  can be a composite component, and can include a substrate having a ceramic material, an overmold material at least partially surrounding the substrate and forming an exterior surface of the component  110 , and an operational component, such as an antenna, integrated or embedded into the overmold material. 
     The component  110  can include one or more apertures or through holes. A transparent material  111  can be disposed in the one or more apertures. In some cases, the transparent material  111  can be visually transparent and can include a ceramic material such as sapphire, or a polymer material such as a polyamide. The transparent material  111  can provide visual access to an exterior environment for one or more components of the device  100 , as described with respect to  FIG. 3 . 
     The housing  101  can include one or more features to receive or couple to other components of the device  100 . For example, the frame  120  can include features, such as an indentation  113  to receive strap  102 , and an aperture  112  to receive a button  114 . The component  110  can include any number of features such as apertures, cavities, indentations, and other mating features to receive and/or attach to one or more other components of the device  100 . 
     Additionally or alternatively, other components of the electronic device  100 , such as individual internal structural components or exterior input components, can be formed from or can include a substrate including a ceramic material and an overmold material at least partially surrounding the substrate and forming an exterior surface thereof. For example, in some cases, the device  100  can include input components, such as one or more buttons  114  and/or a crown  115 , that can be formed from a composite component, as described herein. The composite component can provide strong and durable, yet relatively inexpensive, input components  114 ,  115 . Further, the overmold material can result in input components  114 ,  115  that can have an aesthetically pleasing look and feel for the user. 
     The device  100  of  FIGS. 1 and 2  is merely one example of an electronic device  100  that can include a composite component, such as the housing  101 . Alternatively, the device  100  can include other components including or formed from composite components. For example, the device  100  can include components such as a stiffener, a frame, or other components that are formed from or can include a substrate that includes a ceramic material and an overmold material, at least partially surrounding the substrate, as described herein. Additional electronic devices and designs thereof, including one or more composite components as discussed herein, are expressly contemplated. Further details of example components are provided below with reference to  FIG. 3 . 
       FIG. 3  shows a sectional view of electronic device  100 , including internal components such as processors, memory, circuit boards, batteries, and sensors. Such components can be disposed within an internal volume defined at least partially by the housing  101 , and can be affixed to the housing  101 , via internal surfaces, attachment features, threaded connectors, studs, posts, and/or other fixing features, that are formed into, defined by, or otherwise part of the housing  101 . 
     The device  100  can include internal components, such as a system in package (SiP)  141 , including one or more integrated circuits such as a processors, sensors, and memory. The device  100  can also include a wireless charging coil  142 . The wireless charging coil  142  can be coupled to a battery (not shown) housed in the internal volume of the device  100 . The device  100  can also include one or more sensors  144 , such as optical or other sensors, that can sense or otherwise detect information regarding the environment exterior to the housing  101 . Additional components, such as a haptic engine  145 , can also be included in the device  100 . Other components, such as a battery, a display, and a speaker (all not shown) can be included or housed within the internal volume of the device  100 . 
     As can be seen in  FIG. 3 , the housing  101  can include a back case or a back cover  110  and a frame  120 . In some cases, the back cover  110  can be joined to the frame  120 , and a gasket or seal  143  can be positioned between the back cover  110  and frame  120  to provide for a housing  101  that is substantially impervious to water and/or gases. The frame  120  can include one or more of a variety of materials. For example, the frame  120  can be formed from a metallic material, a ceramic material, an amorphous material such as glass, a polymeric material, and combinations thereof. In some examples, however, the entire housing  101  can be formed from or can be a composite component. 
     The back cover  110  can include a substrate  132  including a ceramic material. The substrate  132  can be, for example, ceramic fibers embedded in or at least partially surrounded by a matrix material. In some examples, the ceramic fibers can be substantially randomly positioned throughout the matrix material, while in some other examples the ceramic fibers can be arranged in a pattern such as a weave. In some cases, the substrate  132  can be a substantially unitary ceramic article and may not include a matrix material. The back cover  110  further includes an overmold material  131  at least partially surrounding the substrate  132  and forming at least a portion of an exterior surface of the back cover  110 . In this example, the overmold material  131  forms a portion of the exterior surface of the device  100 . In some cases where the overmold material  131  can include a polymer material, such as a polyamide material including glass fibers, the overmold material  131  can provide a pleasing look and feel to the exterior of the device  100 , in addition to providing durability, resistance to environmental degradation, and other tangible benefits. 
     An operational component, such as an antenna  133 , can be embedded in the overmold material  131  and can be communicatively coupled to one or more of the internal components of the device  100 . The antenna  133  is illustrated as a metal sheet, although other forms of antennas are expressly contemplated. Further, in some cases, the back cover  110  can include two or more antennas embedded or at least partially surrounded by the overmold material  131 . Additionally, although the antenna  133  is illustrated as being positioned along an edge of the back cover  110 , the antenna  133  can be disposed at any location in the overmold material  131  of the back cover  110 . 
     All or a portion of one or more internal components, for example, the SiP  141 , can be formed from or include a composite component. In some embodiments, the composite component can allow for one or more of such internal components to be light, durable, strong, and inexpensive, as discussed herein. Further, the design of such components can allow for component architectures that may not have previously been able to be achieved. 
     The internal components, such as one or more of components  141 ,  142 ,  144 , and  145 , can be disposed within an internal volume defined, at least partially, by the housing  101 . These components  141 ,  142 ,  144 , and  145  can be affixed to the housing  101  via internal surfaces, attachment features, threaded connectors, studs, posts, and/or other fixing features, that are formed into, defined by, or otherwise part of the housing  101  and/or the cover  103 . 
     The housing  101 , including the back cover  110  formed from a composite component, can be conformable to interior dimensional requirements, as defined by the internal components, such as components  141 ,  142 ,  144 , and  145 . For example, the structure of the housing  101  including a composite back cover  110  can be defined or limited exclusively or primarily by the internal components the housing is designed to accommodate. That is, because a housing  101  including a composite back cover  110  can be extremely light and strong, the housing  101  can be shaped to house the interior components in a dimensionally efficient manner without being constrained by factors other than the dimensions of the components, such as the need for additional structural elements. 
     The composite component  110  of the housing  101  can also be formed by a variety of processes, as discussed herein. In some embodiments, these formation processes can allow for the housing  101  to have a detailed shape or design that is tailored specifically to satisfy one or more needs, such as internal dimensional requirements, without the need for additional features to reinforce the structure of the housing. Additionally, artifacts of the manufacturing process of the housing can be eliminated. 
     Any number or variety of components of an electronic device, for example, electronic device  100 , can be formed from or can include a composite component. The structure of these composite components can be, for example, a substrate including a ceramic material and an overmold material at least partially surrounding the substrate. The structure and materials of the substrate and overmold material, and of the composite component itself, can apply not only to the specific examples discussed herein, but to any number or variety of embodiments. Various embodiments of composite components are described below, with specific reference to  FIG. 4A . 
       FIG. 4A  shows a perspective view of an example composite component  210  that can be, for example, part of a housing of an electronic device. In some cases, the composite component  210  can be a back cover of a housing for an electronic device. In some examples, the composite component  310  can be the entire housing of an electronic device. 
     The composite component  210  can include a substrate  232 , including a ceramic material, and an overmold material  231  at least partially surrounding the substrate  232 . In some examples, the overmold material  231  can form an exterior surface of the component  210 . The component  210  can also include an antenna, or other electronic or operational component, integrated or embedded into the overmold material  231 . 
     The substrate  232  can include a ceramic material. In some cases, the ceramic material can include, for example, ceramic fibers. The ceramic fibers can be embedded in or be at least partially surrounded by a matrix material to form the substrate  232 , as described herein. In some instances, the ceramic fibers can be substantially randomly positioned throughout the matrix material. In other examples, the ceramic fibers can be arranged in a pattern, such as a weave. In some other examples, however, the ceramic material can include any shape or form of ceramic material. For example, the ceramic material can include ceramic particles, pellets, spheres, rods, tubes, fibers, or another form, in any amount or combination, embedded or at least partially surrounded by a matrix material to form the substrate  232 . Additionally, the substrate  232  can include ceramic material and may not include a matrix material. For example, the substrate  232  can be a substantially unitary ceramic body having the shape and design of the substrate  232 . 
     The ceramic material of the substrate  232  can include zirconia, alumina, or combinations thereof. Although, in some cases, the ceramic material of the substrate  232  can include any ceramic material known in the art or discovered in the future. 
     The substrate  232  can include one or more apertures  234  formed therein. For example, where the component  210  can be the back cover of an electronic device, the aperture or apertures  234  can allow one or more internal components of the electronic device to have visual or physical access to the environment exterior to the device. Thus, in some cases, the apertures  234  can be positioned, sized, and/or arranged to correspond to one or more internal components of an electronic device. In some cases, however, the apertures  234  can have alternative or additional purposes. For example, in some cases, the apertures  234  can serve to reduce the weight or amount of material included in the component  210 . 
     The aperture or apertures  234  can be formed in the substrate at any point during the formation or manufacturing of the component  210 . For example, the apertures  234  can be formed during the initial forming process of the substrate  232 , such as an initial molding process. Alternatively, the apertures can be formed by a cutting process, such as a laser cutting process, that occurs at other stages during formation of the component  210 . 
     The apertures  234  can have a material  211  disposed therein. In some examples, the material  211  disposed in the apertures  234  can have a peripheral shape corresponding to the shape of the apertures in which it is disposed. The material  211  can be a transparent material, such as an optically or visually transparent material. In some examples, the material  211  can be transparent to a desired wavelength of light. The transparent material  211  can serve to allow one or more internal components of an electronic device to have visual access to the environment exterior to the device, while still providing environmental protection to the internal components. In some cases, the transparent material  211  can be a polymeric material, a ceramic material, an amorphous material such as glass, or combinations thereof. For example, the transparent material  211  can be sapphire or a polyamide material. 
     An overmold material  231  can at least partially surround the substrate  232 . The overmold material  231  can be any moldable material that is capable of being overmolded at least partially around the substrate  232 . In some examples, the overmold material  231  can be a metallic material, an amorphous material such as glass, a polymeric material, or other appropriate material. In some cases, the overmold material  231  can be a polymer material, such as a polyamide material, although any polymeric material can be used. Further, one or more additional materials can be included in the moldable material of the overmold material  231 . The overmold material  231  can be a polymeric material and can include additional materials disposed therein, such as glass or ceramic material. For example, the overmold material  231  can be a polyamide material and can include glass or ceramic fibers at least partially embedded therein. 
     As can be seen in  FIGS. 4B and 4C , the overmold material  231  can surround and cover one or more exterior surfaces of the substrate  232 , while one or more other exterior surfaces of the substrate  232  can be free of overmold material  231 . For example, where the component  210  is a part of a housing of an electronic device, the overmold material  231  can cover a surface of the substrate  232  defining an exterior surface of the housing, while a surface of the substrate  232  defining an interior volume of the electronic device can be free of the overmold material  231 . Alternatively, the overmold material  231  can completely or substantially surround the substrate  232 . Thus, in some examples, an electronic device including the component  210  can have an exterior surface defined by the overmold material  231 . Further, one or more electronic or operational components, such as an antenna, can be integrated into and/or at least partially surrounded by the overmold material  231 . 
     While the overmold material  231  is depicted as a substantially unitary article in  FIGS. 4A-F , the overmold material  231  can include one or more discrete or non-contiguous portions overmolded onto the substrate  232 . Thus, in some examples, the overmold material  231  can define a portion of an external surface of a device including the component  210 , while the substrate  231  may define a second, different portion of an external surface of the device. Similarly, a surface of the component  210  defining an internal volume or surface of an electronic device can be defined by one or more portions of the overmold material  231  and one or more different portions of the substrate. 
     In some examples where the overmold material  231  defines an exterior surface of a device including the component  210 , the overmold material  231  can provide a pleasing look and/or feel to the surface of the device. The overmold material  231  can also serve to enhance the durability or toughness of the component  210 . For example, the overmold material  231  can serve to absorb shocks and impacts during use to prevent or reduce cracking or chipping of the substrate  232 . 
     The overmold material  231  can have any desired shape or design. For example, as illustrated in  FIGS. 4A-4F , the overmold material  231  can at least partially surround the substrate  232  at a fixed or variable thickness and can additionally include one or more features, structures, protrusions, or elements. For example, the overmold material  231  can include one or more attachment features  236 . The attachment features  236  can be, for example, positioned around a periphery of the substrate  232  and can secure the component  210  to one or more other components of an electronic device. The attachment features  236  can be designed or shaped to receive and engage a fixing member, such as a screw. For example, the engagement features  236  can include threads corresponding to threads of a screw. In some examples, the attachment features  236  can include a cavity, such as a cavity capable of receiving and retaining a fastener, like a nut that can receive a bolt. Other forms of attachment features  236  are expressly contemplated. 
     The ability to include an attachment feature  236  in the overmold material  231  of the component  210  can provide for significantly reduced processing costs and times for attaching the component  210 , relative to a similarly structured component formed entirely of a ceramic material. In order to form attachment features in a component formed entirely of a ceramic material, extensive and delicate processing may be utilized to prevent defects. Accordingly, by forming attachment features  236  in the moldable and relatively easier to process or machine overmold material  231 , the component  210  can have significantly reduced material and processing costs. Meanwhile, the substrate  232  including the ceramic material can still provide for a strong and rigid component  210  compared to a similar component formed entirely of the overmold material  231 . 
     The overmold material  231  can additionally include one or more other desired structures or features. For example, the overmold material  231  can include an aperture  214 . In some instances, the aperture  214  can be positioned in a protrusion or other portion of the overmold material  231  such that the apertures do not expose the substrate  232 . Alternatively, a feature of the overmold material  231 , such as an aperture, can expose or reveal an underlying portion of the substrate  232 . 
     Further, in instances where the substrate  232  can include one or more apertures  234 , the overmold material  231  can also include apertures corresponding in size, shape, and position to the apertures  234  in the substrate  232 . In some examples, the apertures  234  of the substrate and the corresponding apertures of the overmold material  231  can be formed substantially simultaneously. In some other examples, however, the apertures  234  of the substrate  232  can be formed initially and the corresponding apertures of the overmold material  231  can be formed in a subsequent step. 
     The overmold material  231  can be formed at least partially around the substrate  232  by any number of additive manufacturing or molding processes. For example, the overmold material  231  can be formed by an injection molding process using a mold that contains the substrate  232 . Alternatively, the overmold material  231  can be formed by an additive process, such as a 3D printing process. For example, an overmold material  231  can be 3D printed at least partially around the substrate  232 . Processes such as 3D printing can allow for the formation of an overmold material  231  that can have a shape or include features that are not formable by other molding or manufacturing processes. 
     The overmold material  231  can be secured or adhered to the substrate  232  by the mechanical engagement between the overmold material  231  and the substrate  232 . For example, in some examples, one or more features of the substrate  232  can mechanically engage with one or more corresponding features of the overmold material  231 , to retain the overmold material  231  and the substrate  232  together. In some examples, an adhesive is not used to fasten or retain the overmold material  231  and the substrate  232  together. In other examples, and adhesive or other material can be included between the overmold material  231  and the substrate  232 . Additionally, one or more surfaces of the substrate  232  can be prepared or subjected to a treatment prior to overmolding in order to retain the overmold material  231 . For example, in some cases, a surface of the substrate  232  can be subjected to an etching or blasting process that can create microstructures for the overmold material  231  to mechanically engage with. 
     The construction of the component  210 , including a substrate  232  with a ceramic material and an overmold material  231  at least partially surrounding the substrate, can provide for a component  210  that has a high level of strength and rigidity relative to a similar component made substantially or entirely from the overmold material. The enhanced strength provided by the substrate  232  can allow the component  210  to be substantially smaller and lighter than a component made entirely of a polymeric material that has a similar or reduced strength. Further, the relatively low amount of ceramic material included in the component  210  relative to a component made entirely of ceramic material can result in significantly decreased costs and processing time, while maintaining a similar or only slightly reduced level of strength and rigidity. The overmold material  231  can also serve to protect the substrate  232  from chipping and environmental degradation during use. As noted above, the substrate  232  and the overmold material  231  can be combined in any number of configurations, as described below with reference to  FIGS. 5A-8C . 
       FIG. 5A  shows a top view of an example composite component  310  that can be part of a housing of an electronic device, as described herein. As shown in  FIG. 5A , the composite component includes a ceramic composite substrate  332  with an overmold material  331  substantially covering the exterior portion of the ceramic composite substrate. In some cases, the composite component  310  can be a housing or a back cover of a housing for an electronic device. In some examples, the composite component  310  can be the entire housing of an electronic device. The composite component  310  can be substantially similar to, and can include some or all of the features of other composite components described herein, such as, composite component  210  described with respect to  FIGS. 4A-4F . 
       FIG. 5B  shows a perspective cut-away view of the composite component  310 , while  FIG. 5C  shows a sectional view of the component  310 . As can be seen from the figures, the component  310  can include a substrate  332  including a ceramic material, and an overmold material  331  at least partially surrounding the substrate  332 . In some cases, the overmold material  331  can form an exterior surface of the component  310 . The component  310  can also include an antenna  333  or other electronic or operational component integrated or embedded into the overmold material  331 . 
     As can be seen in  FIG. 5C , the overmold material  332  can substantially or entirely cover a lower surface of the substrate  332 , and any side surfaces of the substrate  332 . The overmold material  332  can also at least partially cover a top surface of the substrate  332 . In some examples, such an arrangement of the overmold material  331  can serve to retain the overmold material  331  around the substrate  332 . The component  310  can also include one or more apertures  334  including a transparent material  311  disposed therein. 
     In some cases, the overmold material  331  covering the substrate  332  can have a substantially uniform thickness. In other embodiments, the thickness of the overmold material  331  can vary along the substrate  332 . The overmold material  331  can be from about 0.25 mm thick to about 1 mm thick, or thicker. In some examples, the overmold material  331  can have an average thickness of about 0.5 mm, excluding any features or protrusions of the overmold material  331 . Structures or features of the overmold material  331 , for example, protrusions or attachment features, can have a thickness of up to several millimeters or even a centimeter or more. 
     The substrate  332  can include a ceramic material. The ceramic material can include, for example, ceramic fibers. The ceramic fibers can be embedded in, or at least partially surrounded by, a matrix material to form the substrate  332 , as described herein. In some cases, the ceramic fibers can be arranged in a pattern, such as a weave, with one or more fibers arranged in specific orientations. In some examples, one or more ceramic fibers can extend substantially an entire major dimension of the substrate  332 , such as, one or more of a height, width, or length of the substrate. In some cases where the fibers are arranged in a pattern, the pattern can be a plain weave, a twill weave, a satin weave, a jacquard weave, a unidirectional pattern, a tri-axial pattern, or any other known fiber pattern. 
     In some cases, ceramic fibers can be randomly distributed or positioned throughout the matrix material, while in other cases, the ceramic fibers can be arranged in a pattern, such as a weave. In some examples, however, the ceramic material can include any shape or form of ceramic material. For example, the ceramic material can include ceramic particles, pellets, spheres, rods, tubes, fibers, or other geometries, in any amount or combination, embedded or at least partially surrounded by a matrix material to form the substrate  332 . Additionally, in some cases, the substrate  332  can include ceramic material and may not include a matrix material. For example, the substrate  332  can be a substantially unitary ceramic body having the shape and design of the substrate  332 . 
     Further, as shown in  FIGS. 5B and 5C , the component  310  can include an operational component, such as an antenna  333 , at least partially surrounded by the overmold material  331 . In some cases, the antenna  333  can be positioned substantially adjacent to the substrate  332 , although in other cases, the antenna  333  can be positioned at any location at least partially within the overmold material  331 . One or more portions of the antenna  333  can be configured to connect to, or communicate with, other components of an electronic device. 
     The antenna  333  can include or be formed from a metal material. For example, the antenna  333  can include copper, nickel, aluminum, other conducting materials, and combinations thereof. In some cases, however, the antenna  333  can include any desired material, as long as it can molded with or covered by the overmold material  331 . In some examples, the antenna  333  can include a substantially flat sheet of metal. In other examples, the antenna  333  can include any desired shape to receive and/or transmit wireless signals of one or more desired frequencies. In some examples, the antenna  333  can receive and/or transmit wireless signals at one or more frequencies and can be one or more cellular antenna such as an LTE antenna, a Wi-Fi antenna, a Bluetooth antenna, a GPS antenna, a multi-frequency antenna, or other wireless antenna. The antenna  333  can be communicatively coupled to one or more additional components of an electronic device. Further, in some cases, the ceramic material of the substrate  332  can allow the antenna  333  to transmit and/or receive wireless signals with less interference, attenuation, or shielding than if the antenna  333  was included in a component made entirely of a metal or other housing material. In some cases, the substrate  332  may amplify or otherwise enhance wireless signals received and/or transmitted by the antenna, for example, by reducing noise or increasing the amplification of the signals. 
     In some cases, the antenna  333  can be integrated or otherwise incorporated into the overmold material  331  during a forming process of the overmold material  331 . For example, in some cases, the antenna  333  can be positioned relative to the substrate  332 , such as in a mold, and the overmold material  331  can be formed or solidified around the antenna  333  in a single step. In other examples, a portion of the overmold material  331  can first be formed at least partially surrounding the substrate  332 , followed by the antenna  333  being disposed relative to the first portion of the overmold material  331 . A second portion of the overmold material  331  can then be formed in a second stage, to substantially or entirely surround the antenna  333  with the overmold material  331 . Additional details of alternative component configurations are provided with reference to  FIGS. 6A-6B . 
       FIGS. 6A and 6B  show a top schematic view of a composite component  410 , according to one example. The component  410  can be, for example, part of a housing of an electronic device. In some examples, the composite component  410  can be a housing or a back cover of a housing for an electronic device. In some examples, the composite component  410  can be the entire housing of an electronic device. The composite component  410  can be substantially similar to and can include some or all of the features of other composite components described herein, such as, composite component  210  and  310  described with respect to  FIGS. 4A-4F and 5A-5C . 
       FIG. 6A  illustrates one possible arrangement of ceramic fibers  401 ,  402 , that can be at least partially surrounded by a matrix material to form a substrate  432  of a component  410 . As illustrated, in some cases, during or prior to the formation of the substrate  432  the ceramic fibers  401 ,  402  arranged in a weave can extend past the boundaries of the substrate  432 . In some cases, the fibers  401 ,  402  can be at least partially surrounded by a matrix material and then cut or sized, as desired. In some cases, the fibers  401 ,  402  of the pattern or weave can be substantially entirely surrounded by a matrix material and any fibers  401 ,  402  and/or matrix material extending or disposed outside a desired shape of the substrate  432  can be cut or otherwise removed from the substrate  432 . 
     In some cases, for example as depicted in  FIG. 6B , the fibers  401 ,  402  can be cut or otherwise sized prior to at least partially surrounding with a matrix material, so that a weave or pattern of the fibers  401 ,  402  has substantially a same peripheral shape as the peripheral shape of the substrate  432 . Thus, in some other examples, the fibers  401 ,  402  can be cut, sized, or arranged, as desired, prior to being partially surrounded by the matrix material. The ceramic fibers  401 ,  402  can include any ceramic material, such as zirconia, alumina, or combinations thereof. Further, in some cases, the fibers  401 ,  402  can be cut or otherwise formed to include one or more features of the substrate  432 , such as one or more apertures. For example, as illustrated in  FIG. 6B , the fibers  401 ,  402  of the pattern or weave can be cut to remove those portions of the fibers  401 ,  402  that would otherwise overlay or occlude an aperture formed in the substrate  432 . 
     The ceramic material of the substrate  432  can include a first set of fibers  401  arranged in a first direction and a second set of fibers  402  arranged in a second direction. In some examples, the first and second directions can be substantially perpendicular to one another, although other arrangements are expressly contemplated to vary the relative strength of the substrate in specific directions and orientations. In some examples, the one or more ceramic fibers  401 ,  402  can extend substantially across an entire major dimension of the substrate  432 , such as, one or more of a height, width, or length of the substrate. 
     The fibers  401 ,  402  can be arranged in the substrate  432  according to a pattern, such as a weave. The fibers  401 ,  402  of  FIGS. 6A and 6B  are shown as arranged in a twill weave pattern, although any other desired pattern can be used. For example, in some cases, the pattern can be a plain weave, a twill weave, a satin weave, a jacquard weave, a unidirectional pattern, a tri-axial pattern, or any other pattern. In some cases, the matrix material at least partially surrounds the fibers  401 ,  402  and can be a moldable or curable material, such as an epoxy or resin. In some examples, the matrix material can be any thermoset polymer, thermoplastic polymer, or combinations thereof. The matrix material can include metallic material, amorphous materials such as glass, polymeric materials, and/or combinations thereof. The matrix material can also be substantially transparent to electromagnetic signals. The design flexibility provided by the use of ceramic fibers can allow for a composite component made entirely of the composite material, without or substantially free of overmold material, as detailed below with reference to  FIGS. 7A-7C . 
       FIG. 7A  shows a top view of an example composite component  510  that can be, for example, part of a housing of an electronic device. As shown in  FIGS. 7A-7C , the example composite component  510  is entirely formed of a ceramic composite substrate  532  without, or substantially free of, overmold material. In some examples, the composite component  510  can be a back cover of a housing for an electronic device. Alternatively, the composite component  510  can be the entire housing of an electronic device. 
     As seen in  FIGS. 7B and 7C , the component  510  can be a substantially contiguous and/or unitary body that can include a ceramic material  437 . That is, in some cases, the substrate  532  can have a same shape as the component  510 , and can be free of any overmold material. Thus, in some examples, the component  510  can include a ceramic material  437  at least partially embedded in a matrix material. In some examples, and as illustrated in  FIGS. 7A-7C , the ceramic material  437  can include ceramic fibers. The ceramic fibers  437  can be randomly positioned and/or oriented throughout the matrix material. The component  510  can also include one or more apertures  534 , including a transparent material  511  disposed therein. 
     Further, as shown in  FIGS. 7B and 7C , the component  510  can include an operational component, such as an antenna  533 , at least partially surrounded by the matrix material of the substrate  532 . In other examples, the antenna  533  can be positioned at any location at least partially within the substrate  532 . For example, where the antenna  533  is substantially or entirely surrounded by the substrate  532 , one or more portions of the antenna  533  configured to connect to or communicate with other components of an electronic device can be protruding from or be otherwise free of the substrate  532 . 
     The antenna  533  can include or be formed from a metal material. For example, the antenna  533  can include copper, nickel, aluminum, similar conductive metals, and combinations thereof. In some cases, however, the antenna  533  can include any desired material, as long as it can be formed with the substrate  532 . In some examples, the antenna  533  can include a substantially flat sheet of metal. Although, in some other cases, the antenna  533  can assume any desired shape configured to receive and/or transmit wireless signals of one or more desired frequencies. In some cases, the antenna  533  can receive and/or transmit wireless signals at one or more frequencies and can be, for example, one or more of a cellular antenna such as an LTE antenna, a Wi-Fi antenna, a Bluetooth antenna, a GPS antenna, a multi-frequency antenna, or any other wireless signal antenna. The antenna  533  can be communicatively coupled to one or more additional components of an electronic device. Further, in some cases, the ceramic material  537  of the substrate  532  can allow the antenna  533  to transmit and/or receive wireless signals with less interference, attenuation, or shielding, than if the antenna  533  was included in a component made entirely of a metal or other housing material. In some cases, the substrate  532  may amplify or otherwise enhance wireless signals received and/or transmitted by the antenna, for example, by reducing noise or increasing the amplification of the signals. Additional configurations, including a composite component with a partially exposed ceramic composite and a partially overmolded portion, are detailed below with reference to  FIGS. 8A-8C . 
       FIG. 8A  shows a top view of an example composite component  610  that can be, for example, a housing or part of a housing of an electronic device. As shown in  FIGS. 8A-8C , the example composite component can have a substrate  632  including a ceramic composite and an overmold material  631  that partially covers or surrounds the substrate. In some cases, the composite component  610  can be a back cover of a housing for an electronic device. In some examples, the composite component  610  can be the entire housing of an electronic device. The composite component  610  can be substantially similar to, and can include some or all of the features of other composite components described herein. 
       FIG. 8B  shows a sectional view of the composite component  610  and  FIG. 8C  illustrates a close-up sectional view of the component  610 . As can be seen from the figures, the component  610  can include a substrate  632  including a ceramic material and an overmold material  631  at least partially surrounding the substrate  632 . In some cases, the overmold material  631  can form an exterior surface of the component  610 . The component  610  can also include an antenna  633  or other electronic component integrated or embedded into the overmold material  631 . 
     The substrate  632  can include a ceramic material. In some cases, the ceramic material can include a substantially contiguous and/or unitary body of ceramic material. Thus, in some cases, the substrate  632  may not include a matrix material. For example, the substrate  632  can include a unitary body of zirconia or alumina material, although any ceramic material can be used. The substrate can have any desired size or shape. As discussed herein, the ceramic body of the substrate  632  can impart high strength and rigidity to the component  610 , while the use of an overmold material  631  around the ceramic body of the substrate can provide for reduced processing costs and time, as well as providing protection to the substrate  632  from chipping or environmental attack. 
     Further, as shown in  FIGS. 8B and 8C , the component  610  can include an operational component, such as an antenna  633 , at least partially surrounded by the overmold material  631 . In some cases, the antenna  633  can be positioned substantially adjacent to the substrate  632 , while in other examples, the antenna  633  can be positioned at any location at least partially within the overmold material  631 . In some examples, where the antenna  633  is substantially or entirely surrounded by the overmold material  631 , one or more portions of the antenna  633  configured to connect to or communicate with other components of an electronic device can extend from or beyond the overmold material  631 . 
     The antenna  633  can include or be formed from a metal material. For example, the antenna  633  can include copper, nickel, aluminum, any other metal material, and combinations thereof. In some cases, however, the antenna  633  can include any desired material, as long as it is capable of being formed within the overmold material  631 . In some cases, the antenna  633  can include a substantially flat sheet of metal. In other examples, the antenna  633  can assume any desired shape to receive and/or transmit wireless signals of one or more desired frequencies. In some examples, the antenna  633  can receive and/or transmit wireless signals at one or more frequencies and can be, for example, one or more of a cellular antenna such as an LTE antenna, a Wi-Fi antenna, a Bluetooth antenna, a GPS antenna, a multi-frequency antenna, and/or another similar antenna. The antenna  633  can be communicatively coupled to one or more additional components of the electronic device. Further, the ceramic material of the substrate  632  can allow the antenna  633  to transmit and/or receive wireless signals with less interference, attenuation, or shielding, than if the antenna  633  was included in a component made entirely of a metal or another housing material. In some cases, the substrate  632  can amplify or otherwise enhance wireless signals received and/or transmitted by the antenna, for example, by reducing noise or increasing the amplification of the signals. 
     The antenna  633  can be integrated or otherwise incorporated into the overmold material  631  during a forming process of the overmold material  631  as part of the component  610 . For example, the antenna  633  can be positioned relative to the substrate  632 , such as in a mold, and the overmold material  631  can then be formed or solidified around the antenna  633 . In some other examples, a portion of the overmold material  631  can first be formed at least partially surrounding the substrate  632 , followed by the antenna  633  being positioned relative to the first portion of the overmold material  631 . A second portion of the overmold material  631  can then be formed to substantially or entirely surround the antenna  633 . Additional configurations are provided below with reference to  FIGS. 9A-10B . 
     As shown in  FIG. 9A , the present configuration can be used in the formation of a housing  701  for any electronic device, including a mobile phone or a smart phone  700 . As shown, the smart phone  700  includes a front screen cover  703  and a housing  701  defined by a composite component  710 . As noted above, the composite component  710  can be either a portion of the housing  701  or the entire housing of the smart phone  700 . 
       FIG. 9B  shows a sectional view of the composite component  710 . As can be seen in  FIG. 9B , the composite component  710  can include a substrate  732  including a ceramic material and an overmold material  731  at least partially surrounding the substrate  732 . In some cases, the overmold material  731  can form an exterior surface of the composite component  710 , and the resulting smart phone  710 . The composite component  710  can also include an antenna  733  or other electronic or operational component integrated or embedded into the overmold material  731 . 
     Similar to the embodiments detailed above, the substrate  732  can include a ceramic material as either a substantially contiguous and/or unitary body of ceramic material, a ceramic weave in a matrix, or as ceramic particles distributed within a matrix. As detailed above, each of these configurations impart high strength and rigidity to the component  710 , while the use of an overmold material  731  around the ceramic body of the substrate can provide for reduced processing costs and time, as well as providing protection to the substrate  732  from chipping or environmental attack. 
     The antenna  733  can be at least partially surrounded by the overmold material  731 . In some examples, the antenna  733  can be positioned substantially adjacent to the substrate  732 , while in other examples the antenna  733  can be positioned at any location at least partially within the overmold material  731 . Similar to the antenna detailed above, the antenna  733  can include or be formed from a metal material, such as copper, nickel, aluminum, any other metal material, and combinations thereof. In some cases, the ceramic material of the substrate  732  can allow the antenna  733  to transmit and/or receive wireless signals with less interference, attenuation, or shielding, than if the antenna  733  was included in a component made entirely of a metal or another housing material. In some cases, the substrate  732  can amplify or otherwise enhance wireless signals received and/or transmitted by the antenna, for example, by reducing noise or increasing the amplification of the signals. Alternatively, the present configuration can be incorporated into a tablet computer, as shown in  FIGS. 10A and 10B . 
     As shown in  FIG. 10A , the present configuration can also be used in the formation of a housing  801  for a tablet computer  800 . As shown, the tablet computer  800  includes a front screen cover  803  and a housing  801  defined by a composite component  810 . The composite component  810  can be either a portion of the housing  801 , or the entire housing of the tablet computer  800 . 
       FIG. 10B  shows a sectional view of the composite component  810 . As can be seen in  FIG. 10B , the composite component  810  can include a substrate  832  including a ceramic material and an overmold material  831  at least partially surrounding the substrate  832 . In some cases, the overmold material  831  can form an exterior surface of the composite component  810 , and the resulting smart phone  810 . The composite component  810  can also include an antenna  833  or other electronic component integrated or embedded into the overmold material  831 . 
     Similar to the embodiments detailed above, the substrate  832  can include a ceramic material as either a substantially contiguous and/or unitary body of ceramic material, a ceramic weave in a matrix, or as ceramic particles distributed within a matrix. As detailed above, each of these configurations impart high strength and rigidity to the component  810 , while the use of an overmold material  831  around the ceramic body of the substrate can provide for reduced processing costs and time, as well as providing protection to the substrate  832  from chipping or environmental attack. 
     Similar to the examples provided above, the antenna  833  can be at least partially surrounded by the overmold material  831 . In some examples, the antenna  833  can be positioned substantially adjacent to the substrate  832 , while in other examples the antenna  833  can be positioned at any location at least partially within the overmold material  831 . The antenna  733  can include or be formed from a metal material, such as copper, nickel, aluminum, any other metal material, and combinations thereof. In some cases, the ceramic material of the substrate  832  can allow the antenna  833  to transmit and/or receive wireless signals with less interference, attenuation, or shielding, than if the antenna  833  was included in a component made entirely of a metal or another housing material. In some cases, the substrate  832  can amplify or otherwise enhance wireless signals received and/or transmitted by the antenna, for example, by reducing noise or increasing the amplification of the signals. Details regarding forming the present antenna-permeable structure is provided below, with reference to  FIGS. 11-13 . 
       FIG. 11  illustrates a process flow diagram of an exemplary process for forming a composite component, as described herein. The process  900  for forming the component can include positioning an electronic or operational component, such as an antenna, relative to a substrate including a ceramic material at block  910  and overmolding a material at least partially around the substrate and the electronic component at block  920 . 
     At block  910 , an electronic component is positioned relative to a substrate including a ceramic material. The substrate can include some or all of the features of the substrates described herein. For example, the substrate can include a ceramic material at least partially surrounded by a matrix material. The ceramic material can include ceramic fibers, for example, randomly disposed through the matrix material or arranged in a pattern such as a weave. 
     The electronic component can be positioned relative to the substrate, for example, in a desired position when at least partially surrounded by the overmold material. The electronic component and the substrate can be held in this arrangement by any apparatus or method known in the art or developed in the future. For example, the electronic component and the substrate can be held relative to one another in a mold. In some cases, the electronic component can be an antenna or another operational component, as described herein. 
     At block  920 , a moldable material can be overmolded so that it at least partially surrounds the substrate and the electronic component. In some examples, the material can be overmolded at least partially around both the substrate and the electronic component in a single step. For example, the substrate and the electronic component can be positioned relative to one another in a mold and the material can be injection molded over the substrate and electronic component. In some cases, a portion of the overmold material can first be formed to at least partially surround the substrate, followed by the electronic component being positioned relative to the first portion of the overmold material while a second portion of the material is overmolded around both the substrate and the antenna, substantially or entirely surrounding the antenna with overmold material. Thus, in some cases, block  920  can occur or take place both before and after the positioning of the electronic component in block  910 . 
     The overmold material can be a metallic material, an amorphous material, a polymeric material, a composite material, or combinations thereof. In some cases, the overmold material can be a polymer material such as a polyamide material, although any polymeric material can be used. Further, in some cases, one or more additional materials can be included in the moldable material of the overmold material. For example, the overmold material can be a polyamide material and can include glass fibers embedded therein. 
     The material can be overmolded at block  920  by any number of additive manufacturing or molding processes. For example, in some cases, the overmold material can be formed by an injection molding process using a mold that contains the substrate and the electronic component. In other examples, the material can be overmolded by an additive process, such as a 3D printing process. For example, a material can be 3D printed at least partially around the substrate and an electronic component, as described herein. 3D printing and other precise manufacturing processes can allow for the formation of an overmold material that can assume a shape or include features that cannot be formed by other molding or manufacturing processes. 
       FIG. 12  illustrates a process flow diagram of another exemplary process for forming a composite component. According to  FIG. 12 , the process  1000  for forming the component can include solidifying a matrix material at least partially around a ceramic material to form a substrate at block  1010 . The substrate can then be formed into a desired shape at  1020 . An electronic component, such as an antenna, can then be positioned relative to the substrate at block  1030 . As shown in block  1040 , a material can then be overmolded at least partially around the substrate and the electronic component. 
     At block  1010 , a matrix material is solidified at least partially around a ceramic material. The ceramic material can include any of the ceramic materials described herein, in any combination. For example, the ceramic material can include ceramic fibers. In some cases, the ceramic fibers can be substantially randomly positioned throughout the matrix material, while in some other cases, the ceramic fibers can be arranged in a pattern such as a weave. The ceramic material can include or assume any shape or form of ceramic material. For example, the ceramic material can include ceramic particles, pellets, spheres, rods, tubes, fibers, or other geometries in any amount or combination. In some cases, the ceramic material can be a substantially contiguous and/or a substantially unitary ceramic body. The ceramic material can include zirconia, alumina, or combinations thereof. 
     In some cases, the ceramic material can be positioned in a mold or other apparatus in a desired orientation and the matrix material can be molded at least partially around the ceramic material. Any process for forming a matrix material around the ceramic material can be used, such as, a molding or injection molding process. In some cases, the matrix material can be a thermoset polymer, such as an epoxy or resin. In some cases, the matrix material can be a thermoplastic polymer. In some cases, the matrix material can be a combination of any thermoset and thermoplastic polymer. In some cases, the matrix material can be provided at least partially around the ceramic material in a liquid or viscous form and can then be solidified by curing or cooling to form a substrate. In some other cases, the matrix material can include any matrix material described herein. 
     At block  1020 , the substrate can be formed into a desired shape. In some cases, block  1020  can occur substantially simultaneous with block  1010 . That is, the matrix material can be solidified around the ceramic material into a desired shape. In some cases, however, further processing of the substrate can occur after the matrix material has solidified to form the substrate into a desired shape. For example, any subtractive manufacturing process can be used to form the substrate into a desired shape, including forming one or more features therein, such as apertures. In some cases, the substrate can be cut or machined into a desired shape. For example, a laser-cutter can be used to form the substrate into a desired shape. 
     At block  1030 , an electronic component is positioned relative to a substrate including a ceramic material. The substrate can include some or all of the features of the substrates described herein. The electronic component can be positioned relative to the substrate, in a desired position when at least partially surrounded by the overmold material. The electronic component and the substrate can be held in this arrangement by any apparatus or method known in the art or developed in the future. For example, the electronic component and the substrate can be held relative to one another in a mold. In some cases, the electronic component can be an antenna. 
     At block  1040 , a moldable material can be overmolded so that it at least partially surrounds the substrate and the electronic component. In some cases, the material can be overmolded at least partially around the substrate and the electronic component in a single step process. For example, the substrate and electronic component can be positioned relative to one another in a mold and the material can be injection molded over the substrate and electronic component. In some cases, a portion of the overmold material can be formed at least partially surrounding the substrate in a first stage, and the electronic component can be positioned relative to the first portion of the overmold material while a second portion of the material is overmolded around the substrate and the electronic components so that the electronic component is substantially or entirely surrounded by the overmold material. Thus, in some cases, block  1030  can occur or take place both before and after the positioning of the electronic component in block  1040 . 
     The material overmolded at least partially around the substrate and the electronic component can be a metallic material, an amorphous material, a polymeric material, or any other moldable material. In some cases, the overmold material can be a polymer material such as a polyamide material, although any polymeric material can be used. Further, in some cases, one or more additional materials can be included in the moldable material of the overmold material. For example, the overmold material can be a polyamide material and can include glass fibers embedded therein. 
     The material can be overmolded at block  1040  by any number of additive manufacturing or molding processes. For example, in some cases, the overmold material can be formed by an injection molding process using a mold that contains the substrate and the electronic component. In other examples, the material can be overmolded by an additive process, such as a 3D printing process. For example, a material can be 3D printed at least partially around the substrate and an electronic component, as described herein. 3D printing and other precise manufacturing processes can allow for the formation of an overmold material that can assume a shape or include features that cannot be formed by other molding or manufacturing processes. 
       FIG. 13  illustrates a process flow diagram of another exemplary process for forming a composite component. The process  1100  for forming the component can include positioning an electronic component, such as an antenna, relative to a ceramic material at block  1110  and solidifying a matrix material at least partially around the electronic component and the ceramic material at block  1120 . 
     At block  1110 , an electronic component is positioned relative to a ceramic material. The ceramic material can include some or all of the features of the ceramic materials described herein. For example, the ceramic material can include ceramic fibers, for example, randomly disposed or oriented, or arranged in a pattern such as a weave. 
     The electronic component can be positioned relative to the ceramic material, for example, in a desired position when at least partially surrounded by the matrix material. The electronic component and the ceramic material can be held in this arrangement by any apparatus or method known in the art or developed in the future. For example, the electronic component and the ceramic material can be held or positioned relative to one another in a mold. In some cases, the electronic component can be an antenna. 
     At block  1120 , a matrix material is solidified at least partially around the ceramic material and the electronic component. The ceramic material can include any of the ceramic materials described herein, in any combination. For example, the ceramic material can include ceramic fibers. In some cases, the ceramic fibers can be substantially randomly positioned throughout the matrix material, while in some other cases, the ceramic fibers can be arranged in a pattern such as a weave. The ceramic material can include any shape or form of ceramic material. For example, the ceramic material can include ceramic particles, pellets, spheres, rods, tubes, fibers, or other shape or form in any amount or combination. In some cases, the ceramic material can be a substantially contiguous and/or a substantially unitary ceramic body. The ceramic material can include zirconia, alumina, or combinations thereof. 
     In some cases, the ceramic material and electronic component can be positioned in a mold or other apparatus in a desired orientation and the matrix material can be molded at least partially around the ceramic material and the electronic component. Any process for forming a matrix material around the ceramic material and electronic component can be used, for example, a molding or injection molding process. In some cases, the matrix material can be a thermoset polymer, such as an epoxy or resin. In some cases, the matrix material can be a thermoplastic polymer. In some cases, the matrix material can be any combination of thermoset and thermoplastic polymers. In some cases, the matrix material can be disposed at least partially around the ceramic material and/or electronic component in a liquid or viscous form, and can then be solidified by curing or cooling to form a substrate. In some other cases, the matrix material can include any matrix material, as described herein, or combinations thereof. 
     In some cases, the matrix material can be solidified around the ceramic material and electronic component in a single step process. For example, the ceramic material and electronic component can be positioned relative to one another in a mold and the material can be injection molded over the ceramic material and the electronic component. In some examples, a portion of the matrix material can be formed at least partially surrounding the ceramic material in a first stage, and the electronic component can be positioned relative to the first portion of the matrix material while a second portion of the matrix material is solidified around the ceramic material and the electronic component, so that the electronic component is substantially or entirely surrounded by the matrix material. Thus, in some cases, block  1120  can occur or take place before, during, and/or after the positioning of the electronic component in block  1110 . 
     Any of the features or aspects of the composite components discussed herein can be combined or included in any varied combination. For example, the design and shape of the substrate and/or overmold material is not limited in any way and can be formed by any number of processes, including those discussed herein. Further, the overmold material can be overmolded at least partially around the substrate at any time, even during formation of the substrate, and by any number of processes, including those discussed herein. A composite component, as discussed herein, can be or can form all or a portion of a component, such as a housing, for an electronic device. The composite component can also be or form any number of additional components of an electronic device, including internal components, external components, cases, surfaces, or partial surfaces. 
     Various inventions have been described herein with reference to certain specific embodiments and examples. However, they will be recognized by those skilled in the art that many variations are possible without departing from the scope and spirit of the inventions disclosed herein, in that those inventions set forth in the claims below are intended to cover all variations and modifications of the inventions disclosed without departing from the spirit of the inventions. The terms “including:” and “having” come as used in the specification and claims shall have the same meaning as the term “comprising.” 
     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 meant to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20180925
Publication Date: 20200331
Grant Date: 20200331
Priority Date: 20180925
Inventors: ELY, COLIN M.
SLABAUGH, SCOTT W.
Assignee: APPLE INC
CPC Classifications: [{"code": "B29L2031/3481", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2309/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14786", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2793/009", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C70/545", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q15/08", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/273", "inventive": true, "first": false, "tree": "[]"}, {"code": "D10B2505/02", "inventive": false, "first": false, "tree": "[]"}, {"code": "D10B2101/08", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C70/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "D10B2101/08", "inventive": false, "first": false, "tree": "[]"}, {"code": "C04B2235/5236", "inventive": false, "first": false, "tree": "[]"}, {"code": "C04B2235/5224", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01Q1/273", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0217", "inventive": true, "first": false, "tree": "[]"}, {"code": "G04G17/08", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C70/023", "inventive": true, "first": false, "tree": "[]"}, {"code": "C04B2235/5224", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C70/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/243", "inventive": true, "first": false, "tree": "[]"}, {"code": "D10B2101/08", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K5/0217", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01Q1/273", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D15/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "C04B2235/5236", "inventive": false, "first": false, "tree": "[]"}, {"code": "G04G17/08", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C70/023", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D15/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D15/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "D03D15/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K5/0217", "inventive": true, "first": false, "tree": "[]"}, {"code": "G04G17/08", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 69883891