Yttria-sensitized zirconia
A housing for a portable electronic device is disclosed. The housing is composed of yttria-sensitized zirconia. Yttria-sensitized zirconia has from about 1.5 to about 2.5 mole percent yttria, and more typically about 2 mole percent yttria, and most typically 2 mole percent yttria, in zirconia. Yttria-sensitized zirconia is both tough and able to limit the formation and propagation of micro-cracks. Methods for manufacturing yttria-sensitized zirconia composed housings are also disclosed.
1. An enclosure for an electronic device comprising:
a housing body defining an opening and composed of zirconia and from 1.5 mole percent yttria to 2.5 mole percent yttria;
a cover attached to the housing body and covering the opening to define an enclosed volume; wherein:
a first surface of the housing body is polished;
the first surface has a first amount of monoclinic crystals;
at least a portion of a second surface of the housing body is roughened; and
the second surface has a second amount of monoclinic crystals that is greater than the first amount.
2. The enclosure of claim 1 , wherein:
an internal portion of the housing body located between the first and second surfaces includes tetragonal phase zirconia; and
the first and second surfaces include a combination of monoclinic and tetragonal phase zirconia.
3. The enclosure of claim 1 , wherein the at least a portion of the second surface of the housing body is roughened to form a roughened surface having a surface roughness Ra from about 0.05 to about 0.4 μm.
4. The enclosure of claim 3 , wherein the roughened surface is formed over a stress-prone region having an increased likelihood of experiencing elevated stress as compared to other regions of the housing body.
5. The enclosure of claim 1 , wherein the housing body is composed of zirconia and 2 mole percent yttria.
6. The enclosure of claim 1 , wherein the housing body defines a bottom portion having multiple sidewalls extending therefrom.
7. The enclosure of claim 1 , wherein the enclosed volume is configured to receive a display and multiple electronic components.
8. The enclosure of claim 1 , wherein the electronic device is a wearable electronic device or a mobile phone.
9. An electronic device comprising:
a housing having an exterior surface and an interior surface, the housing composed of yttria-sensitized zirconia;
a display positioned within the housing; and
a cover positioned over the display; wherein
the interior surface of the housing contains a higher percentage of zirconia monoclinic crystals than the exterior surface of the housing.
10. The electronic device of claim 9 , wherein the yttria-sensitized zirconia is composed of zirconia and from 1.5 mole percent to 2.5 mole percent yttria.
11. The electronic device of claim 9 , wherein the yttria-sensitized zirconia is composed of 2 mole percent yttria.
12. The electronic device of claim 9 , wherein the exterior surface is polished.
13. The electronic device of claim 9 , wherein the interior surface of the housing exhibits an increased resistance to micro-fracture propagation as compared to the exterior surface of the housing.
14. The electronic device of claim 9 , wherein an internal portion of the housing located between the interior and exterior surfaces includes tetragonal phase zirconia.
15. A method of forming a housing substrate for an electronic device, comprising:
forming a housing substrate composed of yttria-sensitized zirconia, the housing substrate having an interior surface and an exterior surface;
polish at least a portion of the exterior surface; and
roughen at least a portion of the interior surface to induce a phase shift in the yttria-sensitized zirconia and produce an increased amount of monoclinic crystals as compared to the exterior surface.
16. The method of claim 15 , wherein the yttria-sensitized zirconia is composed of zirconia and from 1.5 mole percent yttria to 2.5 mole percent yttria.
17. The method of claim 15 , wherein the exterior surface and interior surface have a greater amount of monoclinic crystals as compared to an internal portion of the housing substrate located between the exterior and interior surfaces.
18. The method of claim 15 , wherein roughening the portion of the interior surface of the housing substrate increases a resistance to micro-crack propagation as compared to the exterior surface of the housing substrate.
19. The housing of claim 15 , wherein the roughened portion of the interior surface results in a surface roughness having an Ra from 0.05 to 0.4 μm.
20. The method of claim 15 , wherein:
the roughening is performed by blasting the interior surface with alumina particles; and
the polishing is performed by applying a diamond resin pad to the exterior surface.