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US 8,895,362 B2Granted
Methods for bonding material layers to one another and resultant apparatus
AssigneeCorning Incorporated
InventorsJames Gregory Couillard, Christopher Paul Daigler, Jiangwei Feng, Yawei Sun, Lili Tian, Ian David Tracy
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Abstract
Methods and apparatus provide for a structure, including: a first glass material layer; and a second material layer bonded to the first glass material layer via bonding material, where the bonding material is formed from one of glass frit material, ceramic frit material, glass ceramic frit material, and metal paste, which has been melted and cured.
Claims20
A method, comprising:
- disposing raw bonding material onto a first surface of one or both of first and second glass material layers, wherein:
- (i) the disposition is carried out using screen printing to produce a pattern of the raw bonding material onto the first and/or second glass material layers, and (ii) the raw bonding material is formed from one of glass frit material, ceramic frit material, glass ceramic frit material, and metal paste;
- heating the first and/or second glass material layers on which the pattern has been disposed to a temperature sufficient to burn out organic materials that may be present;
- further heating the first and/or second glass material layers in excess of a melting temperature of the raw bonding material such that the raw bonding material melts and becomes glazed to the first and/or second glass material layers;
- pressing the first and second glass material layers together such that:
- (i) the pattern or patterns of bonding material is disposed therebetween, and (ii) when respective patterns of melted bonding material are disposed on the first and second glass material layers, aligning the respective patterns of melted bonding material in registration with one another prior to the pressing step;
- and
- further heating the first and second glass material layers, while maintaining the pressing action, to re-melt the bonding material and bond the first and second glass material layers together, wherein a resultant flatness of the bonded first and second glass material layers is one of:
- (i) about 0.75 μm per mm or better;
- and (ii) about 0.4 μm per mm or better.
7 more elements
A method, comprising:
- disposing raw bonding material onto a first surface of one or both of first and second glass material layers, wherein:
- (i) the disposition is carried out using screen printing to produce a pattern of the raw bonding material onto the first and/or second glass material layers, and (ii) the raw bonding material is formed from one of glass frit material, ceramic frit material, glass ceramic frit material, and metal paste;
- heating the first and/or second glass material layers on which the pattern has been disposed to a temperature sufficient to burn out organic materials that may be present;
- further heating the first and/or second glass material layers in excess of a melting temperature of the raw bonding material such that the raw bonding material melts and becomes glazed to the first and/or second glass material layers;
- pressing the first and second glass material layers together such that:
- (i) the pattern or patterns of bonding material is disposed therebetween, and (ii) when respective patterns of melted bonding material are disposed on the first and second glass material layers, aligning the respective patterns of melted bonding material in registration with one another prior to the pressing step;
- and
- further heating the first and second glass material layers, while maintaining the pressing action, to re-melt the bonding material and bond the first and second glass material layers together, wherein:
- the pattern includes an X-Y directional array of cells, each cell being characterized by a continuous rectangular perimeter of the raw bonding material;
- the second glass material layer includes an array of apertures therethrough;
- and
- the continuous rectangular perimeter of the raw bonding material of each cell is in registration with a respective one of the apertures of the second glass sheet at least one of:
- (i) when the first and second glass material layers are pressed together, and (ii) when the raw bonding material is disposed on the second glass material layer using screen printing.
10 more elements
An apparatus, comprising:
- a first glass material layer;
- and
- a second material layer bonded to the first glass material layer via bonding material,
- wherein the bonding material is formed from one of glass frit material, ceramic frit material, glass ceramic frit material, and metal paste, which has been melted and cured,
- wherein a flatness of the bonded first and second glass material layers is one of:
- (i) about 0.75 μm per mm or better;
- and (ii) about 0.4 μm per mm or better.
4 more elements
An apparatus, comprising:
- a first glass material layer;
- and
- a second material layer bonded to the first glass material layer via bonding material,
- wherein the bonding material is formed from one of glass frit material, ceramic frit material, glass ceramic frit material, and metal paste, which has been melted and cured, wherein:
- the second glass material layer includes an array of apertures therethrough;
- and
- the bonding material is patterned forming a continuous perimeter around each of the apertures of the second glass material sheet.
4 more elements
Dependencies are inferred from the claim text.