Ceramic Composite Housing with Glass Infill

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Solution Overview

Problem

Electronic device housings face challenges in balancing properties such as strength, appearance, abrasion resistance, and electromagnetic shielding, as single materials like metal, glass, or ceramics excel in some aspects but fall short in others, leading to high costs and durability issues.

Innovation Solution

A ceramic composite housing with a substrate of ceramic material and a transparent infill material, such as glass, where the infill material has a lower melting point than the ceramic, forming a solid body with enhanced mechanical and aesthetic properties, and 3D printing allows for intricate designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal housing is used, then strength and toughness are improved, but electromagnetic shielding performance deteriorates

Engineering Contradiction:

Improvehousing strengthVSAvoidelectromagnetic shielding

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent employs a composite housing structure combining ceramic material (for strength and electromagnetic shielding) with transparent material (for aesthetics and electromagnetic transparency). This composite approach allows simultaneous achievement of mechanical strength, electromagnetic shielding, and visual appeal that single materials cannot provide alone.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If a glass housing is used, then abrasion resistance and electromagnetic transparency are improved, but strength and toughness deteriorate

Engineering Contradiction:

Improveabrasion resistanceVSAvoidhousing strength

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The composite structure integrates ceramic material providing high strength and toughness with transparent material providing abrasion resistance and electromagnetic transparency. The ceramic substrate reinforces the housing structurally while the transparent material maintains scratch resistance and signal transparency.

Inventive Principle:

Principle #40Composite materials

3Strength

If ceramic material is used, then abrasion resistance and strength are improved, but electromagnetic shielding performance and manufacturing cost deteriorate

Engineering Contradiction:

Improvehousing strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent uses a composite of ceramic and transparent material to achieve high strength and abrasion resistance. The transparent material can be applied through cost-effective processes like injection molding or coating, reducing the overall manufacturing complexity and cost compared to solid ceramic while maintaining the desired mechanical properties.

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If a single material is used for housing, then manufacturing simplicity is improved, but performance balance across multiple properties deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidperformance balance

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The composite housing design combines ceramic material and transparent material, each contributing different properties. This allows the housing to simultaneously achieve strength, abrasion resistance, electromagnetic shielding, and electromagnetic transparency - a performance balance unattainable with single materials - while maintaining manufacturing feasibility through established composite processing techniques.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The ceramic composite housing achieves higher strength and durability than glass while reducing manufacturing costs and time, with enhanced scratch resistance and electromagnetic shielding, and aesthetically pleasing designs.

Implementation Method 1

a substrate with a matrix of ceramic material defining a network of interstitial regions and a transparent material occupying at least some of the interstitial regions of the substrate

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Implementation Method 2

The transparent material can have a melting point lower than a melting point of the matrix of ceramic material

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

The transparent material can have a melting point lower than a melting point of the matrix of ceramic material

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS11667585B2Ceramic substrate with glass fill for decoration and housing materials

Publication Date: 2023.06.06 APPLE INC

AI summary

A ceramic composite article includes a substrate including a matrix of ceramic material defining a network of interstitial regions and a transparent material occupying at least some of the interstitial regions of the substrate. The transparent material can have a melting point lower than a melting point of the ceramic material. The matrix of ceramic material can be formed by a 3D printing process.