Laser bonding assembly including hermetically sealed glass structure and cover glass

Abstract

In an embodiment, a laser bonding assembly includes a glass structure, a metal foil, and a first cover glass. The glass structure includes a first glass substrate defining a first major surface and a second glass substrate defining a second major surface opposite the first major surface. The glass structure further includes a peripheral edge extending about a periphery thereof between the first major surface and the second major surface. The laser bonding assembly further includes a metal foil configured to surround the peripheral edge. The metal foil is connected to the glass structure via a foil-glass laser bond. The laser bonding assembly further includes a first cover glass connected to the glass structure and / or the metal foil. The laser bonding assembly further includes a frame disposed adjacent to the first cover glass. The glass structure and the metal foil are at least partially surrounded by the frame and the first cover glass.

Description

[0001] Cross-citation of related applications

[0002] This application claims the priority benefit of U.S. Provisional Application Serial No. 63 / 639819, filed April 29, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to hermetically sealed glass assemblies. Specifically, this disclosure relates to laser-bonded assemblies comprising a hermetically sealed glass structure and a cover glass. Background Technology

[0004] Glass structures can be laser-bonded to metal foil to form hermetically sealed glass structures. These hermetically sealed glass structures are increasingly used in consumer electronics devices and other devices that can benefit from a hermetically sealed environment. Consumer electronics devices typically undergo increased durability requirements (e.g., scratch resistance, drop resistance) while also meeting hermetically sealed requirements. However, some existing hermetically sealed glass structures may not be robust enough to meet both requirements.

[0005] Therefore, it would be advantageous to provide hermetically sealed glass structures with various cover glass arrangements to form laser bonding assemblies that overcome the problems of existing hermetically sealed glass structures. Summary of the Invention

[0006] A first aspect of this disclosure includes a laser bonding assembly comprising: a glass structure including: (i) a first glass substrate defining a first main surface; (ii) a second glass substrate disposed adjacent to the first glass substrate and defining a second main surface opposite to the first main surface; and (iii) a peripheral edge extending between the first main surface and the second main surface around a periphery of the glass structure; a metal foil surrounding the peripheral edge around the periphery of the glass structure and connected to the glass structure via one or more foil-glass laser bonding portions; a first cover glass connected to one or more of the glass structure and the metal foil; and a frame disposed adjacent to the first cover glass, the glass structure and the metal foil being at least partially surrounded by the frame and the first cover glass.

[0007] A second aspect of this disclosure includes a laser bonding assembly comprising: a glass structure including: (i) a first glass substrate defining a first main surface; (ii) a second glass substrate disposed adjacent to the first glass substrate and defining a second main surface opposite to the first main surface; and (iii) a peripheral edge extending between the first main surface and the second main surface around a periphery of the glass structure; a polymer seal surrounding the peripheral edge around the periphery of the glass structure; a first cover glass disposed adjacent to the polymer seal and the glass structure; and a second cover glass disposed adjacent to the polymer seal and the glass structure and opposite to the first cover glass, the glass structure and the polymer seal being disposed in a cavity between the first cover glass and the second cover glass, wherein the second cover glass is connected to one or more of the glass structure and the first cover glass via one or more glass-to-glass laser bonding portions. Attached Figure Description

[0008] Figure 1 This is a schematic cross-sectional view of a laser bonding assembly according to an embodiment, the laser bonding assembly including a hermetically sealed glass structure, a metal foil, a frame and at least one cover glass;

[0009] Figure 2 This is a schematic cross-sectional view of a laser bonding assembly according to an embodiment, the laser bonding assembly including a hermetically sealed glass structure, a metal foil, a frame, and at least two cover glasses;

[0010] Figure 3 This is a schematic cross-sectional view of a laser bonding assembly according to an embodiment, the laser bonding assembly including a hermetically sealed glass structure and... Figure 1 or Figure 2 The metal foil is configured differently, along with a frame and at least two cover glass panels;

[0011] Figure 4 This is a schematic cross-sectional view of a laser bonding assembly according to an embodiment, the laser bonding assembly including a hermetically sealed glass structure, a polymer seal, and at least two cover glasses;

[0012] Figure 5 This is a schematic cross-sectional view of a laser bonding assembly according to an embodiment, the laser bonding assembly including a hermetically sealed glass structure and... Figure 4 Polymer seals configured differently and at least two cover glass;

[0013] Figure 6 This is a schematic cross-sectional view of a laser bonding assembly, which is similar to... Figure 5 The laser bonding assembly differs in that at least one laser bonding section is omitted between the glass structure and the cover glass;

[0014] Figure 7 It is a description and Figure 1 and Figure 2 A schematic cross-sectional view of an embodiment of a glass structure and metal foil used together with laser bonding components;

[0015] Figure 8 It is a description and Figure 3 A schematic cross-sectional view of an embodiment of a glass structure and metal foil used together with laser bonding components;

[0016] Figure 9 yes Figure 1 A simplified schematic top view of a laser bonding assembly to show aspects of one or more foil-glass laser bonding sections;

[0017] Figure 10 yes Figure 2 A simplified schematic top view of a laser bonding assembly to show aspects of one or more foil-glass laser bonding sections;

[0018] Figure 11 yes Figure 3 A simplified schematic top view of the laser bonding assembly, illustrating aspects of one or more foil-to-glass laser bonding portions and one or more glass-to-glass laser bonding portions; and

[0019] Figure 12 yes Figure 4 A simplified schematic top view of the laser bonding assembly is provided to illustrate aspects of one or more glass-to-glass laser bonding portions of the laser bonding assembly. Detailed Implementation

[0020] To facilitate an understanding of the principles of this disclosure, reference will now be made to embodiments illustrated in the accompanying drawings and described in the following written description. It should be understood that this disclosure is not intended to limit the scope of the disclosure. It should be further understood that this disclosure includes any changes and modifications to the illustrated embodiments, and includes further applications of the principles disclosed herein that would commonly occur to those skilled in the art to which this disclosure pertains.

[0021] As used herein, when used in a list having two or more items, the term "and / or" means that any one of the listed items may be used alone, or any combination of two or more of the listed items may be used. For example, if a composition is described as containing components A, B, and / or C, the composition may contain A alone; B alone; C alone; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C.

[0022] In this document, relational terms such as first and second, top and bottom are used only to distinguish one entity or action from another, and do not necessarily require or imply any actual such relationship or order between such entities or actions.

[0023] As used herein, the term "about" means that a quantity, size, formulation, parameter, and other quantity and characteristic is not and need not be precise, but may be approximate and / or larger or smaller as required, reflecting tolerances, conversion factors, rounding, measurement errors, and other factors known to those skilled in the art. When the term "about" is used to describe a value or range endpoint, this disclosure should be understood to include the specific value or endpoint mentioned. Whether or not the numerical or range endpoints in the specification are listed with "about," the numerical or range endpoints are intended to include two embodiments: one modified by "about" and one not modified by "about." It should be further understood that each endpoint of a range is significant relative to and independent of the other endpoint.

[0024] Concentration, quantity, and other numerical data may be expressed or presented in range format herein. It should be understood that such range format is used solely for convenience and brevity, and therefore should be flexibly interpreted to include not only the numerical values ​​explicitly stated as the limits of the range, but also all individual numerical values ​​or subranges encompassed within said range, as if each numerical value and subrange were explicitly stated. For example, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly stated values ​​of about 1 to about 5, but also the individual values ​​and subranges within the indicated range. Thus, included in this numerical range are, for example, individual values ​​of 2, 3, and 4, and subranges such as 1-3, 2-4, 3-5, etc., as well as 1, 2, 3, 4, and 5 individually. The same principle applies to ranges that list only one numerical value as a minimum or maximum value. Furthermore, this interpretation should apply regardless of how broad the range is or what characteristics it describes.

[0025] Unless defined elsewhere in association with a particular term or phrase, the terms “substantially,” “essentially,” and variations thereof, as used herein, are intended to indicate that the described feature is equal to or approximately equal to a value or description. For example, a “substantially flat” surface is intended to mean a flat or nearly flat surface. Furthermore, “essentially” is intended to mean that two values ​​are equal or approximately equal. In some embodiments, “essentially” may mean values ​​that differ from each other by about 10%, such as values ​​that differ from each other by about 5%, or values ​​that differ from each other by about 2%.

[0026] As used in this article, directional terms such as up, down, right, left, front, back, top, bottom, above, below, etc., are only for reference to the drawn diagram and are not intended to imply absolute orientation.

[0027] As used herein, the terms “the,” “a,” or “an” mean “at least one,” and should not be limited to “only one” unless explicitly indicated otherwise. Thus, by way of example, unless the context explicitly indicates otherwise, references to “component” include embodiments having two or more such components.

[0028] As described in this article, "hermetic bonding" and "hermetic seal" refer to components that include hermetic seals according to MIL-STD-750E test method 1071.9.

[0029] This document discloses embodiments of laser bonding components configured to address one or more of the edge strength and fixation problems described above. Figures 1 to 3 This illustrates a laser-bonded assembly that utilizes one or more metal foils combined with other structures to form a hermetically sealed package. Figures 4 to 6 This invention illustrates a laser bonding assembly that utilizes polymer seals instead of one or more metal foils to form a hermetically sealed package. In various embodiments, each laser bonding assembly includes a glass structure comprising at least two glass substrates disposed adjacent to each other. Figure 7 Describing and Figure 1 and 2 Examples of glass structures and metal foils used together with laser bonding components. Figure 8 Describing and Figure 3 Examples of glass structures and metal foils used together with laser bonding components. Figures 9 to 11 They are Figures 1 to 3 A simplified schematic top view of a laser bonding assembly, showing the relative positions of the laser bonding portions of the various elements used to connect and / or seal the laser bonding assembly. Figure 12 yes Figure 4 A simplified schematic top view of a laser bonding assembly, showing the relative positions of the laser bonding portions of the various elements used to connect and / or seal the laser bonding assembly.

[0030] Now for reference Figure 1 and Figure 7 The image shows a laser bonding assembly 10a in a first configuration. For ease of description, the laser bonding assembly 10a in the first configuration may be interchangeably referred to as the first laser bonding assembly 10a, but such reference should not be construed as limiting the scope of this disclosure. The first laser bonding assembly 10a includes a glass structure 100 configured for hermetic sealing. Figure 7As best shown, the glass structure 100 includes a first glass substrate 104 defining a first main surface 108 of the glass structure 100 and a second glass substrate 112 disposed adjacent to the first glass substrate 104 and defining a second main surface 116 of the glass structure 100. The second main surface 116 is opposite to the first main surface 108, as shown in the figure. Figure 1 and 7 As shown in the image.

[0031] In this embodiment, the first glass substrate 104 and the second glass substrate 112 are not in direct contact with each other, allowing one or more other glass substrates, polymer layers, or (electronic) components (e.g., interchangeably referred to as "filler" or "filling layer") to be placed between them. For example, Figure 1 and 7 The glass structure 100 shown includes a filler layer 118 disposed between a first glass substrate 104 and a second glass substrate 112. This filler layer 118 positions other glass substrates, polymer layers, or (electronic) components between the first glass substrate 104 and the second glass substrate 112, protecting them from environmental conditions such as pressure changes, moisture, and bodily fluids. In an embodiment, the first glass substrate 104 and the second glass substrate 112 may be in direct contact (not shown), without a filler layer between them.

[0032] The glass structure 100 further includes a peripheral edge or side 120 extending between the first main surface 108 and the second main surface 116 surrounding a periphery 124 (e.g., the outermost portion or boundary) of the glass structure 100. When viewed in a direction perpendicular to the first main surface 108 and the second main surface 112 (e.g., interchangeably referred to as the thickness direction), the periphery 124 of the glass structure 100 can have any shape, such as including linear portions, curved portions, or both. In embodiments, the periphery 124 of the glass structure 100 can have a free-form shape (e.g., without straight lines). In embodiments, the peripheral edge 120 includes a surface adjacent to and / or defining one or more of the first glass substrate 104, the second glass substrate 112, and the filler layer of the glass structure 100.

[0033] Peripheral edge 124 may include a continuous surface, said continuous surface including portions of the surfaces of the first glass substrate 104, the second glass substrate 112, and the filling layer, such as... Figure 1 and 7As shown in the diagram. The peripheral edge 124 may include a continuous surface that comprises portions of the surfaces of the first glass substrate 104 and the second glass substrate 112 when the first glass substrate 104 and the second glass substrate 112 are in direct contact (e.g., the glass structure does not include a filler layer). The peripheral edge 124 may also include a discontinuous surface extending between the first main surface 108 and the second main surface 116, for example, when the first glass substrate 104 and the second glass substrate 112 are adjacent but not in direct contact with each other, and no filler layer is disposed between them.

[0034] In one embodiment, the refractive index of the first glass substrate 104 and the second glass substrate 112 can be greater than or equal to 1.4 and less than or equal to 2.4. In another embodiment, the refractive index of the first glass substrate 104 and the second glass substrate 112 can be greater than or equal to 1.4, greater than or equal to 1.5, or even greater than or equal to 1.6. In yet another embodiment, the refractive index of the first glass substrate 104 and the second glass substrate 112 can be less than or equal to 2.4, less than or equal to 2.3, or even less than or equal to 2.2. In embodiments, the refractive indices of the first glass substrate 104 and the second glass substrate 112 may be greater than or equal to 1.4 and less than or equal to 2.4, greater than or equal to 1.4 and less than or equal to 2.3, greater than or equal to 1.4 and less than or equal to 2.2, greater than or equal to 1.5 and less than or equal to 2.4, greater than or equal to 1.5 and less than or equal to 2.3, greater than or equal to 1.5 and less than or equal to 2.2, greater than or equal to 1.6 and less than or equal to 2.4, greater than or equal to 1.6 and less than or equal to 2.3, or even greater than or equal to 1.6 and less than or equal to 2.2, or any and all subranges formed by any of these endpoints. It should be understood that in some embodiments, the first glass substrate 104 and the second glass substrate 112 may have refractive index values ​​different from each other.

[0035] In embodiments, the first glass substrate 104 and the second glass substrate 112 may comprise glass or glass-ceramic. By way of non-limiting examples, the first glass substrate 104 and the second glass substrate 112 may comprise borate glass, borosilicate glass, phosphate-based glass, silicon carbide glass, soda-lime silicate glass, aluminosilicate glass, alkaline aluminosilicate glass, borosilicate glass, alkaline borosilicate glass, aluminoborosilicate glass, alkaline aluminoborosilicate glass, or alkaline aluminosilicate glass. In embodiments requiring relatively high refractive index glass (e.g., refractive index greater than or equal to 1.4 and less than or equal to 2.4), the first glass substrate 104 and the second glass substrate 112 may comprise borate glass or borosilicate glass. In embodiments, the first glass substrate 104 and the second glass substrate 112 may undergo chemical strengthening, chemical tempering, and / or thermal tempering. Non-limiting examples of suitable commercially available glass substrates include EAGLE from Corning Incorporated. Lotus TM , and Glass, including its chemically strengthened, chemically tempered, and / or heat-tempered versions. In embodiments, glass that has been chemically strengthened by ion exchange and glass-ceramics may be suitable as substrates. In other embodiments, the first glass substrate 104 and / or the second glass substrate 112 may be strengthened glass-glass laminates.

[0036] In an embodiment, the first glass substrate 104 and the second glass substrate 112 may include a coating (not shown). In an embodiment, the coating may include a refractive index similar to that of the first glass substrate 104 and the second glass substrate 112. In an embodiment, the coating may include a polymer coating, an anti-reflective (AR) coating, an oleophobic coating, an anti-glare coating, or a scratch-resistant coating.

[0037] Still referencing Figure 1 and Figure 7 The first laser bonding assembly 10a further includes a metal foil 200 configured to surround the peripheral edge 120 of the glass structure 100. As used herein, the terms "encircle," "encircles," etc., mean when... Figure 7 As indicated by arrow 128, when viewed from a position laterally outside or outside the glass structure 100 and the metal foil 200 in a direction parallel to the first main surface 108 and the second main surface 116, the metal foil 200 is shaped and / or positioned to cover, surround and / or cover the entire peripheral edge 120 (e.g., the surface that forms or defines the peripheral edge).

[0038] Metal foil 200 is connected to glass structure 100 via one or more foil-glass laser bonding portions 202. As used herein, "foil-glass laser bonding portion" refers to a mechanical connection (directly) established between metal foil 200 and a glass material (e.g., glass or glass-ceramic) of another component or part of the laser bonding assembly, and formed via a laser beam directed near the contact point between metal foil 200 and the glass material. Aspects of the fixtures and processes that may be used to form one or more foil-glass laser bonding portions 202 are described later in this disclosure.

[0039] In embodiments, the first glass substrate 108 and the second glass substrate 112 may be formed of a material that is substantially transparent to a laser beam of a selected wavelength used to attach the metal foil to the glass. The term "substantially transparent" means that the laser beam of the selected wavelength is transmitted through the material without being substantially absorbed or scattered. For example, in embodiments, the material that is substantially transparent to a laser beam of a selected wavelength may be a material exhibiting a transmittance of greater than or equal to 90% at the selected wavelength. In embodiments, the first glass substrate 108 and the second glass substrate 112 may optionally be substantially transparent to light wavelengths greater than or equal to 300 nm and less than or equal to 1100 nm, or even greater than or equal to 330 nm and less than or equal to 750 nm.

[0040] In an embodiment, the first glass substrate 108 and the second glass substrate 112 may undergo surface treatment before being bonded to the metal foil 200. For example, in an embodiment, the first glass substrate 108 and the second glass substrate 112 may be polished until their surfaces exhibit relatively low surface roughness values, which can enhance bonding with the metal foil 200. In an embodiment, the first main surface 108 of the first glass substrate 104 and / or the second main surface 116 of the second glass substrate 112 may be polished until the first main surface 108 and / or the second main surface 116 exhibit an average surface roughness (Ra) of less than or equal to 1 μm, less than or equal to 0.5 μm, or even less than or equal to 0.25 μm.

[0041] The smooth surfaces allow the first glass substrate 108 and the second glass substrate 112 to be positioned in close contact with the metal foil 200 (e.g., within a few μm of each other). Additionally, the first glass substrate 108 and the second glass substrate 112 can be cleaned with water and / or solvents to remove any debris and / or material (oil, grease, etc.) present on the surfaces. Removing any debris allows the first glass substrate 108 and the second glass substrate 112 to be positioned in close contact with the metal foil 200, thereby better facilitating laser bonding of the metal foil 200 to the glass structure 100.

[0042] like Figure 7As best shown, the metal foil 200 includes a first foil portion 204 extending toward the glass structure 100 and connected to a first main surface 108 at a first contact location. In an embodiment, the first foil portion 204 includes a first foil surface 208, which is connected to the first main surface 108 at the first contact location via a first foil-glass laser bonding portion 202a of one or more foil-glass laser bonding portions 202. The metal foil 200 further includes a second foil portion 212 extending toward the glass structure 100 and connected to a second main surface 116 at a second contact location. In an embodiment, the second foil portion 212 includes a second foil surface 216, which is connected to the second main surface 116 at the second contact location via a second foil-glass laser bonding portion 202b of one or more foil-glass laser bonding portions 202.

[0043] In one embodiment, the metal foil 200 may be a monolithic body, such that the first foil portion 204 and the second foil portion 212 are integral monolithic features, and after the first foil portion 204 and the second foil portion 212 are connected to the glass structure 100 via the first foil-glass laser bonding portion 202a and the second foil-glass laser bonding portion 202b, respectively, no further bonding (e.g., laser bonding or otherwise) is required to hermetically seal the glass structure 100. In another embodiment, the first foil portion 204 and the second foil portion 212 may be separate entities, and after they are connected to the glass structure 100 via the first foil-glass laser bonding portion 202a and the second foil-glass laser bonding portion 202b, respectively, they are joined together via foil-to-foil laser bonding portion 220 to hermetically seal the glass structure 100. As used herein, a “foil-to-foil laser bond” refers to a mechanical connection established (directly) between different portions of a metal foil 200 (e.g., a first foil portion 204 and a second foil portion 212) and formed via a laser beam directed near the contact location between the different portions of the metal foil 200. In an embodiment, the metal foil 200 includes a third foil portion 222 extending away from the glass structure 100, the first foil portion 204, and the second foil portion 212. In an embodiment, the foil-to-foil laser bond 220 is positioned along the third foil portion 222. Aspects of the fixtures and processes that may be used to form the foil-to-foil laser bond 220 are described later in this disclosure.

[0044] In an embodiment, the metal foil 200 includes an inner periphery 228 (e.g., the innermost periphery) and an outer periphery 232 (e.g., the outermost periphery). The glass structure 100 includes a central region 136 ( Figure 9One or more of the first glass substrate 104, the second glass substrate 112, and (optionally) the filler layer 118 can interact (e.g., directly and / or indirectly) with the external environment surrounding the first laser bonding assembly 10a through the central region. In an embodiment, the inner periphery 228 of the metal foil 200 surrounds at least a portion of the central region 136 of the glass structure 100 to expose (e.g., not cover) the central region 136. In an embodiment, the distal end of the first foil portion 204 of the metal foil 200 defines the inner periphery 228 on a first side (e.g., the bottom side) of the first laser bonding assembly 10a. In an embodiment, the distal end of the second foil portion 212 defines the inner periphery 228 on a second side (e.g., the top side) of the first laser bonding assembly 10a. In an embodiment, the distal end of the third foil portion 222 defines the outer periphery 232.

[0045] In an embodiment, the first foil portion 204 and the second foil portion 212 of the metal foil 200 can be respectively connected to the first glass substrate 200 and the second glass substrate 202, such that the inner periphery 228 on the first side (e.g., the bottom side) of the first laser bonding assembly 10a at least partially overlaps with the inner periphery 228 on the second side (e.g., the top side) of the first laser bonding assembly 10a, thereby exposing the first glass substrate 104 and the second glass substrate 112 through the inner periphery 228 on the first side and the inner periphery 228 on the second side and providing a window through the glass structure 100. In an embodiment, for example... Figure 1 , 7 As shown in Figure 9, the inner periphery 228 on the first side is aligned with the inner periphery 228 on the second side, such that the inner periphery 228 on the first side and the inner periphery 228 on the second side completely overlap.

[0046] In one embodiment, the thickness of the first foil portion 204 may be less than or equal to 50 μm. In another embodiment, the thickness of the first foil portion 204 may be greater than or equal to 3 μm and less than or equal to 50 μm. In yet another embodiment, the thickness of the first foil portion 204 may be greater than or equal to 5 μm, greater than or equal to 10 μm, or even greater than or equal to 20 μm. In yet another embodiment, the thickness of the first foil portion 204 may be less than or equal to 50 μm, less than or equal to 40 μm, or even less than or equal to 30 μm. In an embodiment, the thickness of the first foil portion 204 may be greater than or equal to 3 μm and less than or equal to 50 μm, greater than or equal to 5 μm and less than or equal to 40 μm, greater than or equal to 5 μm and less than or equal to 30 μm, greater than or equal to 10 μm and less than or equal to 50 μm, greater than or equal to 10 μm and less than or equal to 40 μm, greater than or equal to 10 μm and less than or equal to 30 μm, greater than or equal to 20 μm and less than or equal to 50 μm, greater than or equal to 20 μm and less than or equal to 40 μm, or even greater than or equal to 20 μm and less than or equal to 30 μm, or any and all sub-ranges formed by any of these endpoints.

[0047] In an embodiment, the first foil portion 204 may include aluminum, aluminum alloy, stainless steel, nickel, nickel alloy, silver, silver alloy, titanium, titanium alloy, tungsten, tungsten alloy, gold, gold alloy, copper, copper alloy, bronze, iron, or a combination thereof. In an embodiment, the first foil portion 204 may include a metal combined with another non-metallic material.

[0048] In an embodiment, the first foil portion 204 may be formed of a material whose melting point allows for successful bonding with the glass substrate. In an embodiment, the melting point of the first foil portion 204 may be less than or equal to 1800°C, less than or equal to 1700°C, or even less than or equal to 1600°C.

[0049] In an embodiment, the first foil portion 204 may be formed of a material that is substantially opaque to a laser beam of a selected wavelength. The term "substantially opaque" means that when the laser beam contacts the material, the laser beam of the selected wavelength is substantially absorbed rather than transmitted through the material. For example, in an embodiment, the material that is substantially opaque to a laser beam of a selected wavelength may be a material that exhibits an absorbance of greater than or equal to 35% at said wavelength.

[0050] In one embodiment, the first foil portion 204 may have the same or similar average surface roughness (Ra) as the first glass substrate 104 to similarly allow the first glass substrate 104 to be placed in close contact with the first foil portion 204. In another embodiment, the second foil portion 212 may have properties substantially similar to or the same as the first foil portion 204 as described above.

[0051] Still referencing Figure 1 and Figure 7 The first laser bonding assembly 10a further includes a first cover glass 300, which is connected to one or more of the glass structure 100 and the metal foil 200. Figure 1 As best shown, a second foil portion 212 of the metal foil 200 is configured to be attached to the first cover glass 300 at a third contact location. In an embodiment, the second foil portion 212 includes a third foil surface 224, which is attached to the first cover glass 300 at the third contact location via a third foil-glass laser bonding portion 202c of one or more foil-glass laser bonding portions 202. In an embodiment, the third foil surface 224 of the second foil portion 212 is additionally or alternatively attached to the first cover glass 300 at the third contact location via an optically clear adhesive (OCA).

[0052] In one embodiment, the refractive index of the first cover glass 300 may be the same as or similar to the refractive index of one or both of the first glass substrate 104 and the second glass substrate 112. In another embodiment, the refractive index of the first cover glass 300 may be different from the refractive index of one or both of the first glass substrate 104 and the second glass substrate 112. In another embodiment, the glass or glass-ceramic of the first cover glass 300 may be the same as or similar to the glass or glass-ceramic of one or both of the first glass substrate 104 and the second glass substrate 112. In yet another embodiment, the glass or glass-ceramic of the first cover glass 300 may be different from the glass or glass-ceramic of one or both of the first glass substrate 104 and the second glass substrate 112.

[0053] In embodiments, the first cover glass 300 may be chemically strengthened, chemically tempered, and / or thermally tempered. Non-limiting examples of suitable commercially available glass materials for the first cover glass 300 include EAGLE from Corning Incorporated. Lotus TM , and Glass, including its chemically strengthened, chemically tempered, and / or heat-tempered versions. In embodiments, glass and glass-ceramics that have been chemically strengthened by ion exchange may be suitable as the first cover glass 300. In embodiments, the first cover glass 300 may be a strengthened glass-glass laminate. In an exemplary embodiment, the first cover glass 300 is cut to size, edge-finished, and chemically strengthened via ion exchange, such that its surface and edges are significantly strengthened, particularly compared to cover glass that has not been edge-finished and has not been chemically strengthened (e.g., via ion exchange).

[0054] In embodiments where the refractive index of the first cover glass 300 differs from the refractive index of one or both of the first glass substrate 104 and the second glass substrate 112 of the glass structure 100, a refractive index matching material may be incorporated at the interface between them. In such embodiments, the refractive index matching material can eliminate interface problems. In embodiments, the refractive index matching material may be a liquid. In embodiments, the refractive index matching material may be compliant, such that it does not transfer stress from the first cover glass to the glass structure. In embodiments, the first cover glass 300 may be formed of a glass compatible with chemical strengthening and having the same refractive index as the glass structure, allowing the use of an optically transparent adhesive between them.

[0055] Still referencing Figure 1 and Figure 7 The first laser bonding assembly 10a further includes a frame 400 disposed adjacent to the first cover glass 300. For example... Figure 1 As best shown, the glass structure 100 and the metal foil 200 are at least partially surrounded by the frame 400 and the first cover glass 300. The frame 400 is preferably formed of metal, but it can be formed of other materials, such as plastic, reinforced plastic (e.g., carbon fiber filler, glass filler, etc.), or a similar rigid and impact-resistant material that can support the first cover glass 300 when attached to the frame 400. In an embodiment, the first cover glass 300 is mechanically attached to the frame 400. The first cover glass 300 can be mechanically attached to the frame 400 in a manner similar to how a cover glass is attached to a metal frame of a cellular phone. This mechanical attachment can handle stress and impact on the first cover glass 300. In an embodiment, before the first cover glass 300 is mechanically attached to the frame 400, it is attached to the glass structure 100 and / or the metal foil 200 (e.g., forming a sub-assembly including the glass structure 100, the metal foil 200, and the first cover glass 300).

[0056] Now for reference Figure 9 , showing Figure 1 A simplified schematic top view of the first laser bonding assembly 10a, to show aspects of one or more foil-glass laser bonding portions 202 and (optionally) foil-to-foil laser bonding portions 220. Figure 9 The view is simplified because most features of the first laser bonding assembly 10a are shown as completely transparent, and the frame 400 is not shown. For simplicity, the perimeter 124 of the glass structure 100, the inner perimeter 228 of the metal foil 200, and the outer perimeter 232 of the metal foil 200 are depicted with dashed lines because these features are... Figure 9 The view is positioned below the first cover glass 300. One or more foil-glass laser bonding portions 202 and (optionally) foil-foil laser bonding portions 220 are depicted using bold lines to emphasize their general structure.

[0057] As described above, the use of the foil-to-foil laser bonding portion 220 can depend on the configuration of the metal foil 200. In an embodiment, such as Figure 9 As shown, when the metal foil 200 is configured as two or more distinct bodies (e.g., one body includes a first foil portion 204 and at least another body includes a second foil portion 212), the foil-to-foil laser bonding portion 220 can be used to join the first foil portion 204 and the second foil portion 212 together. After the first foil portion 204 and the second foil portion 212 are connected to the glass structure 100 via one or more foil-to-glass laser bonding portions 202, the distinct bodies can be mechanically joined together to hermetically seal the glass structure 100. If the metal foil is configured as a monolithic body, such that the first foil portion 204 and the second foil portion 212 are integral features of the monolithic body, and after the first foil portion 204 and the second foil portion 212 are connected to the glass structure 100 via one or more foil-to-glass laser bonding portions 202, no further bonding (e.g., laser bonding or otherwise) is required to hermetically seal the glass structure 100, then the foil-to-foil laser bonding portion 220 can be optional.

[0058] like Figure 9 As shown, each of one or more foil-to-glass laser bonding portions 202 (e.g., first foil-to-glass laser bonding portion 202a, second foil-to-glass laser bonding portion 202b, and third foil-to-glass laser bonding portion 202c) extends along a corresponding closed profile 236 surrounding the central region 136 of the glass structure 100. Similarly, the foil-to-foil laser bonding portion 220 extends along a closed profile 238 surrounding the central region 136 of the glass structure 100. As used herein, a “closed profile” means that the laser bonding portion follows a continuous (e.g., uninterrupted) path, wherein linear segments and / or curves defining the shape of the path connect or intersect such that the path begins and ends at the same point. In an embodiment, the first foil-to-glass laser bonding portion 202a extends along a first closed profile 236a, the second foil-to-glass laser bonding portion 202b extends along a second closed profile 236b, and the third foil-to-glass laser bonding portion 202c extends along a third closed profile 236c.

[0059] Now for reference Figure 1 and Figure 9 Although the first foil-glass laser bonding portion 202a, the second foil-glass laser bonding portion 202b, and the third foil-glass laser bonding portion 202c are spaced apart from each other in the thickness direction, as Figure 1 As shown in the cross-section, but these laser-bonded portions are depicted as... Figure 9In the top view, it extends along a single closed profile (e.g., the closed profile associated with reference numerals 236, 236a, 236b, 236c) because all these laser-bonded portions are substantially laterally aligned with each other, such as Figure 1 As shown in the figure, foil-to-foil laser bonding portions 220 and foil-to-foil laser bonding portions 220 are arranged laterally outward from the first foil-to-glass laser bonding portion 202a, the second foil-to-glass laser bonding portion 202b, and the third foil-to-glass laser bonding portion 202c, and the first foil-to-glass laser bonding portion 202a, the second foil-to-glass laser bonding portion 202b, and the third foil-to-glass laser bonding portion 202c, respectively, along their extended closed contours 238.

[0060] In an embodiment, one or more foil-glass laser bond portions 202 are formed via one or more welding steps, in which a laser beam passes along a corresponding contact position between the metal foil 200 and the glass material to promote line bonding between the metal foil 200 and the glass material. For example, the laser beam may pass along a first contact position to promote line bonding between a first main surface 108 of the glass structure 100 and a first foil surface 208 of a first foil portion 204 of the metal foil 200 (e.g., along a first closed profile 236a of the first foil-glass laser bond portion 202a). In an embodiment, the first foil-glass laser bond portion 202a may have a first bonding width t1 greater than or equal to 5 μm and less than or equal to 100 μm. Furthermore, the laser beam may surround the inner periphery 228 of the first foil portion 204, such that the first foil-glass laser bond portion 202a between the first main surface 108 and the first foil surface 208 surrounds the inner periphery 228 of the first foil portion 204.

[0061] The laser beam can also pass along the second contact location to facilitate line bonding between the second main surface 116 of the glass structure 100 and the second foil surface 216 of the second foil portion 212 of the metal foil 200 (e.g., along the second foil-glass laser bonding portion 202b of the second closed profile 236b). In an embodiment, the second foil-glass laser bonding portion 202b may have a second bonding width t2 greater than or equal to 5 μm and less than or equal to 100 μm. Furthermore, the laser beam may surround the inner periphery 228 of the second foil portion 212, such that the second foil-glass laser bonding portion 202b between the second main surface 116 and the second foil surface 216 surrounds the inner periphery 228 of the second foil portion 212.

[0062] The laser beam can also pass along the third contact location to facilitate line bonding between the first cover glass 300 and the third foil surface 224 of the second foil portion 212 of the metal foil 200 (e.g., a third foil-glass laser bonding portion 202c along the third closed profile 236c). In an embodiment, the third foil-glass laser bonding portion 202c may have a third bonding width t3 greater than or equal to 5 μm and less than or equal to 100 μm. Furthermore, the laser beam may surround the inner periphery 228 of the second foil portion 212, such that the third foil-glass laser bonding portion 202c between the first cover glass 300 and the third foil surface 224 surrounds the inner periphery 228 of the second foil portion 212.

[0063] In an embodiment, the foil-to-foil laser bond 220 is formed via one or more welding steps, in which a laser beam passes along the contact points between different portions of the metal foil 200 to facilitate line bonding between the different portions of the metal foil 200. For example, in an embodiment where the metal foil 200 is configured as two or more different bodies (e.g., one body includes a first foil portion 204 and at least another body includes a second foil portion 212), the laser beam may pass along the contact points between portions of the first foil portion 204 and the second foil portion 212 (e.g., not connected to the glass structure 100) to facilitate line bonding between the first foil portion 204 and the second foil portion 212 of the metal foil 200 (e.g., along the foil-to-foil laser bond 220 of the closed profile 238). In an embodiment, the foil-to-foil laser bond 220 may have a bonding width t greater than or equal to 5 μm and less than or equal to 100 μm. Furthermore, the laser beam can surround the inner periphery 228 of the first foil portion 204 and / or the second foil portion 212 and the periphery 124 of the glass structure 100, such that the foil-to-foil laser bonding portion 220 between the first foil portion 204 and the second foil portion 212 surrounds the inner periphery 228 of the first foil portion 204 and / or the second foil portion 212 and the periphery 124 of the glass structure 100.

[0064] Examples of fixtures and processes (including laser parameters) that can be used to form one or more foil-to-glass laser bonding portions 202 and / or foil-to-foil laser bonding portions 220 to hermetically seal the glass structure 100 and connect the glass structure 100 to the first cover glass 300 are described in U.S. Patent Application Publication No. 2024 / 0058895, which is incorporated herein by reference in its entirety.

[0065] The process for forming one or more foil-glass laser bonding portions 202 disclosed herein utilizes a low-energy laser to minimize associated thermal defects in the region near the bonding portion by reducing the maximum bonding depth. The maximum bonding depth can refer to the distance the metal foil penetrates the glass substrate during the welding step. In such embodiments, a reduced maximum bonding depth of less than or equal to 600 μm can be achieved. In some embodiments, the maximum bonding depth can be less than or equal to 10 μm. By minimizing the maximum bonding depth, laser defects within the bonding location can be minimized. Furthermore, minimizing the maximum bonding depth minimizes the amount of material required to achieve the desired bonding between the metal foil and the glass substrate, while also increasing the adaptability of the glass structure.

[0066] Now for reference Figure 2 and Figure 7 The diagram illustrates a laser bonding assembly 10b in a second configuration. For ease of description, the laser bonding assembly 10b in the second configuration may be interchangeably referred to as the second laser bonding assembly 10b, but such reference should not be construed as limiting the scope of this disclosure. The second laser bonding assembly 10b includes some elements that are the same as or substantially similar to those of the first laser bonding assembly 10a. Elements of the second laser bonding assembly 10b that are the same as or substantially similar to those of the first laser bonding assembly 10a (e.g., in terms of structure, material, characteristics, manufacturing process, etc.) are identified using the same reference numerals. New or different elements of the second laser bonding assembly 10b are identified using unique reference numerals.

[0067] The second laser bonding assembly 10b includes a glass structure 100, a metal foil 200, and a first cover glass 300, as described above. The glass structure 100 is configured to be hermetically sealed (e.g., via the metal foil 200). The glass structure 100 includes a first glass substrate 104 and a second glass substrate 112 defining a first main surface 108 and a second main surface 116, respectively. Optionally, the glass structure 100 of the second laser bonding assembly 10b includes a filler layer 118 as described above with reference to the first laser bonding assembly 10a. The glass structure 100 further includes a peripheral edge 120 extending between the first main surface 108 and the second main surface 112 surrounding a periphery 124 of the glass structure 100.

[0068] The metal foil 200 of the second laser bonding assembly 10b is configured to surround the peripheral edge 120 of the glass structure 100 around its periphery 124. The metal foil 200 is connected to the glass structure 100 via one or more foil-to-glass laser bonding portions 202. For example, the metal foil 200 includes a first foil portion 204 having a first foil surface 208, which is connected to a first main surface 108 of the first glass substrate 104 at a first contact location via a first foil-to-glass laser bonding portion 202a. The metal foil 200 also includes a second foil portion 212 having a second foil surface 216, which is connected to a second main surface 116 of the second glass substrate 112 at a second contact location via a second foil-to-glass laser bonding portion 202b. The metal foil 200 may be a monolithic body, which may or may not include the foil-to-foil laser bonding portion 220. The metal foil 200 may include separate, distinct bodies (e.g., one body includes a first foil portion 204 and at least another body includes a second foil portion 212), after which the first foil portion 204 and the second foil portion 212 are connected to the glass structure 100 via one or more foil-glass laser bonding portions 202, and the distinct bodies may be mechanically joined together via foil-foil laser bonding portions 220 to hermetically seal the glass structure 100.

[0069] The first cover glass 300 of the second laser bonding assembly 10b is connected to one or more of the glass structure 100 and the metal foil 200. For example, a second foil portion 212 having a third foil surface 224 is connected to the first cover glass 300 at a third contact position via a third foil-glass laser bonding portion 202c. The third foil surface 224 of the second foil portion 212 may additionally or alternatively be connected to the first cover glass 300 at the third contact position via an optically clear adhesive (OCA).

[0070] Still referencing Figure 2 and Figure 7 The second laser bonding assembly 10b further includes a frame 420 disposed adjacent to the first cover glass 300. Figure 2As best shown, the glass structure 100 and the metal foil 200 are at least partially surrounded by the frame 420 and the first cover glass 300. The frame 420 is preferably formed of metal, but it can be formed of other materials, such as plastic, reinforced plastic (e.g., carbon fiber filled, glass filled, etc.), or a similar rigid and impact-resistant material that can support the first cover glass 300 when attached to the frame 420. In an embodiment, the first cover glass 300 is mechanically attached to the frame 420. The first cover glass 300 can be mechanically attached to the frame 420 in a manner similar to how a cover glass is attached to a metal frame of a cellular phone. This mechanical attachment can handle stress and impact on the first cover glass 300. In an embodiment, before the first cover glass 300 is mechanically attached to the frame 420, the first cover glass 300 is attached to the glass structure 100 and / or the metal foil 200 (e.g., forming a sub-assembly including the glass structure 100, the metal foil 200, and the first cover glass 300).

[0071] The second laser bonding assembly 10b further includes a second cover glass 320 adjacent to the frame 420 and disposed opposite to the first cover glass 300, such that the glass structure 100 and the metal foil 200 are disposed between the first cover glass 300 and the second cover glass 320. Figure 2 As best shown, a first foil portion 204 of the metal foil 200 is configured to be attached to the second cover glass 320 at a fourth contact location. In an embodiment, the first foil portion 204 includes a fourth foil surface 240, which is attached to the second cover glass 320 at the fourth contact location via a fourth foil-glass laser bonding portion 202d in one or more foil-glass laser bonding portions 202. In an embodiment, the fourth foil surface 240 of the first foil portion 204 is additionally or alternatively attached to the second cover glass 320 at the fourth contact location via an optically clear adhesive (OCA). In an embodiment, the second cover glass 320 may be the same as or substantially similar to the first cover glass 300 in terms of structure, material, and / or properties, or the second cover glass 320 may be different from the first cover glass 300 in terms of structure, material, and / or properties. The advantage of the second laser bonding assembly 10b, which includes the first cover glass 300 and the second cover glass 320, is that it is scratch-resistant and protects both sides of the assembly.

[0072] Now for reference Figure 1 and Figure 2The frame 420 of the second laser bonding assembly 10b may have structural differences compared to the frame 400 of the first laser bonding assembly 10a. For example, the frame 420 of the second laser bonding assembly 10b may be thinner than the frame 400 of the first laser bonding assembly (e.g., relative to the direction perpendicular to the first main surface 108 and the second main surface 116 of the glass structure 100) because the second cover glass 320 of the second laser bonding assembly 10b is configured to additionally support and / or surround (e.g., protect) the glass structure 100 and the metal foil 200. In embodiments, the frame 420 of the second laser bonding assembly 10b may be the same as or substantially similar to the frame 400 of the first laser bonding assembly 10a in terms of material and / or properties, or the frame 420 may be different from the frame 400 in terms of material and / or properties.

[0073] Now for reference Figure 10 , showing Figure 2 A simplified schematic top view of the second laser bonding assembly 10b, to show aspects of one or more foil-glass laser bonding portions 202 and (optionally) foil-foil laser bonding portions 220. Figure 10 The view is simplified because most features of the second laser bonding assembly 10b are shown as completely transparent and the frame 420 is not shown. For simplicity, the perimeter 124 of the glass structure 100, the inner perimeter 228 of the metal foil 200, and the outer perimeter 232 of the metal foil 200 are depicted with dashed lines because these features are... Figure 10 In the view, it is positioned below the first cover glass 300 and the second cover glass 320. In an embodiment, the corresponding (outer) peripheries of the first cover glass 300 and the second cover glass 320 may have the same shape and be aligned, such as... Figure 10 As shown, or the perimeter may have different shapes and / or different alignments. One or more foil-glass laser bonding portions 202 and (optionally) foil-to-foil laser bonding portions 220 are depicted using bold lines to emphasize their general structure.

[0074] like Figure 10 As shown, the first foil-glass laser bonding portion 202a extends along the first closed profile 236a, the second foil-glass laser bonding portion 202b extends along the second closed profile 236b, the third foil-glass laser bonding portion 202c extends along the third closed profile 236c, and the foil-to-foil laser bonding portion 220 extends along the closed profile 238. In an embodiment, the fourth foil-glass laser bonding portion 202d of the second laser bonding assembly 10b similarly extends along the fourth closed profile 236d.

[0075] Now for reference Figure 2 and Figure 10Although the first foil-glass laser bonding portion 202a, the second foil-glass laser bonding portion 202b, the third foil-glass laser bonding portion 202c, and the fourth foil-glass laser bonding portion 202d are spaced apart from each other in the thickness direction, as Figure 2 As shown in the cross-section, but these laser-bonded portions are depicted as... Figure 10 In the top view, it extends along a single closed profile (e.g., the closed profile associated with reference numerals 236, 236a, 236b, 236c, 236d), because all these laser-bonded portions are substantially laterally aligned with each other, such as Figure 2 As shown in the diagram, foil-to-foil laser bonding portions 220 and 220 are arranged laterally outward from the first foil-to-glass laser bonding portion 202a, the second foil-to-glass laser bonding portion 202b, the third foil-to-glass laser bonding portion 202c, and the fourth foil-to-glass laser bonding portion 202d, and the first foil-to-glass laser bonding portion 202a, the second foil-to-glass laser bonding portion 202b, the third foil-to-glass laser bonding portion 202c, and the fourth foil-to-glass laser bonding portion 202d, respectively, along their extended closed contours 238.

[0076] In an embodiment, the first foil-glass laser bonding portion 202a, the second foil-glass laser bonding portion 202b, the third foil-glass laser bonding portion 202c, and (optionally) the foil-to-foil laser bonding portion 220 of the second laser bonding assembly 10b can be formed using the same or substantially the same laser beam welding steps used to form the corresponding laser bonding portions of the first laser bonding assembly 10a. Additionally, the laser beam can also pass along the fourth contact location to facilitate line bonding between the second cover glass 320 and the fourth foil surface 240 of the first foil portion 204 of the metal foil 200 (e.g., the fourth foil-glass laser bonding portion 202d along the fourth closed profile 236d). In an embodiment, the fourth foil-glass laser bonding portion 202d can have a fourth bonding width t greater than or equal to 5 μm and less than or equal to 100 μm. Furthermore, the laser beam can surround the inner periphery 228 of the first foil portion 204, such that the fourth foil-glass laser bonding portion 202d between the second cover glass 320 and the fourth foil surface 240 surrounds the inner periphery 228 of the first foil portion 204.

[0077] The fixtures and processes (including laser parameters) for forming one or more foil-glass laser bonding portions 202 and / or foil-foil laser bonding portions 220 to hermetically seal the glass structure 100 of the first laser bonding assembly 10a and connect the glass structure 100 to the first cover glass 300 of the first laser bonding assembly 10a can be used to form one or more foil-glass laser bonding portions 202 and / or foil-foil laser bonding portions 220 to hermetically seal the glass structure 100 of the second laser bonding assembly 10b and connect the glass structure 100 to the first cover glass 300 and the second cover glass 320 of the second laser bonding assembly 10b.

[0078] Now for reference Figure 3 and Figure 8 The diagram illustrates a laser bonding assembly 10c in a third configuration. For ease of description, the laser bonding assembly 10c in the third configuration may be interchangeably referred to as the third laser bonding assembly 10c, but such reference should not be construed as limiting the scope of this disclosure. The third laser bonding assembly 10c includes some elements that are the same as or substantially similar to those of the first laser bonding assembly 10a and / or the second laser bonding assembly 10b. Elements of the third laser bonding assembly 10c that are the same as or substantially similar to those of the first laser bonding assembly 10a and / or the second laser bonding assembly 10b (e.g., in terms of structure, material, characteristics, manufacturing process, etc.) are identified using the same reference numerals. New or different elements of the third laser bonding assembly 10c are identified using unique reference numerals.

[0079] The third laser bonding assembly 10c includes a glass structure 100, a first cover glass 300, a second cover glass 320, and a frame 420, as described above. In an embodiment, the glass structure 100 of the third laser bonding assembly 10c is configured to be hermetically sealed by one or more of the first cover glass 300, the second cover glass 320, and the metal foil 250. The glass structure 100 includes a first glass substrate 104 and a second glass substrate 112 defining a first main surface 108 and a second main surface 116, respectively. Optionally, the glass structure 100 of the third laser bonding assembly 10c includes a filler layer 118 as described above with reference to the first laser bonding assembly 10a and the second laser bonding assembly 10b. The glass structure 100 further includes a peripheral edge 120 extending between the first main surface 108 and the second main surface 112 surrounding a periphery 124 of the glass structure 100.

[0080] The metal foil 250 of the third laser bonding assembly 10c is configured to surround the peripheral edge 120 of the glass structure 100 around its periphery 124. The metal foil 250 is connected to the glass structure 100 via one or more foil-glass laser bonding portions 202, which are similar to the one or more foil-glass laser bonding portions 202 described with reference to the first laser bonding assembly 10a and the second laser bonding assembly 10b. The metal foil 250 of the third laser bonding assembly 10c has a different configuration than the metal foil 200 of the first laser bonding assembly 10a and the second laser bonding assembly 10b. Figure 3 and 8 As shown, the metal foil 250 of the third laser bonding assembly 10c has a barrel-shaped or stepped three-dimensional configuration. The barrel shape of the metal foil 250 of the third laser bonding assembly 10c can have a specific manufacturing efficiency, as described later in this disclosure.

[0081] Still referencing Figure 3 and Figure 8 The metal foil 250 includes a first foil portion 204 extending toward the glass structure 100 and connected to a first main surface 108 at a first contact location. In an embodiment, the first foil portion 204 includes a first foil surface 208, which is connected to the first main surface 108 at the first contact location via a first foil-glass laser bonding portion 202a of one or more foil-glass laser bonding portions 202. The metal foil 250 further includes a second foil portion 212 extending away from the glass structure 100 and connected to the first cover glass 300 at a second contact location. In an embodiment, the second foil portion 212 includes a second foil surface 216. Figure 8 The second foil surface is connected to the first cover glass 300 at a second contact position via a second foil-glass laser bonding portion 202b in one or more foil-glass laser bonding portions 202.

[0082] In an embodiment, the metal foil 250 of the third laser bonding assembly 10c includes an inner periphery 228 (e.g., the innermost periphery) and an outer periphery 232 (e.g., the outermost periphery). The glass structure 100 includes a central region 136 ( Figure 11One or more of the first glass substrate 104, the second glass substrate 112, and (optionally) the filler layer 118 can interact (e.g., directly and / or indirectly) with the external environment surrounding the third laser bonding assembly 10c through the central region. In an embodiment, the inner periphery 228 of the metal foil 250 surrounds at least a portion of the central region 136 of the glass structure 100 to expose (e.g., not cover) the central region 136. In an embodiment, the distal end of the first foil portion 204 of the metal foil 250 (e.g., overlapping with the glass structure 100) defines the inner periphery 228 on a first side (e.g., the bottom side) of the third laser bonding assembly 10c. In an embodiment, the distal end of the second foil portion 212 (e.g., furthest from the glass structure 100) defines the outer periphery 232 on a second side (e.g., the top side) of the third laser bonding assembly 10c. In an embodiment, the first foil portion 204 and the second foil portion 212 can be integrally connected via an intermediate foil portion of the metal foil 250. In this embodiment, the intermediate foil portion extends substantially parallel to the peripheral edge 120 of the glass structure 100.

[0083] In an embodiment, the first foil portion 204 and the second foil portion 212 of the third laser bonding assembly 10c may have the same or substantially similar characteristics as the first foil portion 204 and the second foil portion 212 of the first laser bonding assembly 10a and / or the second laser bonding assembly 10b (e.g., in terms of thickness, material, melting point, optical transmittance / absorbance, surface roughness (Ra), etc.).

[0084] like Figure 3 As best shown herein, one or more of the first cover glass 300 and the second cover glass 320 of the third laser bonding assembly 10c can be connected to the glass structure 100 via one or more glass-to-glass laser bonding portions 344. As used herein, "glass-to-glass laser bonding portion" refers to a mechanical connection (directly) established between the glass material (e.g., glass or glass-ceramic) of the (first) component or part of the third laser bonding assembly 10c and the glass material of at least the (second) component or part of the third laser bonding assembly 10c, and formed via a laser beam directed near the contact location between the glass materials of the (first) and (second) components.

[0085] In one embodiment, the first cover glass 300 is connected to the second main surface 116 of the glass structure 100 via a first glass-to-glass laser bond 344a of one or more glass-to-glass laser bond portions 344 (e.g., at a third contact location). In another embodiment, the second cover glass 320 is connected to the first main surface 108 of the glass structure 108 via a second glass-to-glass laser bond 344b of one or more glass-to-glass laser bond portions 344 (e.g., at a fourth contact location). In another embodiment, the first cover glass 300 is additionally or alternatively connected to the second main surface 116 of the glass structure 100 at the third contact location via an optically clear adhesive (OCA). In another embodiment, the second cover glass 320 is additionally or alternatively connected to the first main surface 108 of the glass structure 100 at the fourth contact location via an optically clear adhesive (OCA).

[0086] In one embodiment, the second main surface 116 of the second glass substrate 112 is substantially adjacent to the surface of the first cover glass 300 along which the first glass-to-glass laser bonding portion 344a is formed, such that the third contact position can be positioned along any portion of the second main surface 116. In another embodiment, the first main surface 108 of the first glass substrate 104 is substantially adjacent to the surface of the second cover glass 320 along which the second glass-to-glass laser bonding portion 344b is formed, such that the fourth contact position can be positioned along any portion of the first main surface 108.

[0087] Still referencing Figure 3 The first cover glass 300 and the second cover glass 320 are disposed adjacent to the frame 420 on opposite sides, such that the glass structure 100 and the metal foil 250 are disposed between the first cover glass 300 and the second cover glass 320. In an embodiment, the first cover glass 300 and the second cover glass 320 of the third laser bonding assembly 10c can be mechanically attached to the frame 420 in a similar manner to the mechanical attachment of the first cover glass 300 and the second cover glass 320 of the second laser bonding assembly 10b to the frame 420.

[0088] Now for reference Figure 11 , showing Figure 3 A simplified schematic top view of the third laser bonding assembly 10c, to show aspects of one or more foil-glass laser bonding portions 202 and one or more glass-glass laser bonding portions 344. Figure 11 The view is simplified because most features of the third laser bonding assembly 10c are shown as completely transparent and the frame 420 is not shown. For simplicity, the perimeter 124 of the glass structure 100, the inner perimeter 228 of the metal foil 250, and the outer perimeter 232 of the metal foil 250 are depicted with dashed lines because these features are... Figure 11The view shows it positioned below the first cover glass 300. One or more foil-glass laser bonding portions 202 and one or more glass-glass laser bonding portions 344 are depicted using bold lines to emphasize their general structure.

[0089] like Figure 11 As shown, each of one or more foil-to-glass laser bonding portions 202 (e.g., first foil-to-glass laser bonding portion 202a and second foil-to-glass laser bonding portion 202b) of the third laser bonding assembly 10c extends along a corresponding closed profile 236 surrounding the central region 136 of the glass structure 100. Similarly, each of one or more glass-to-glass laser bonding portions 344 of the third laser bonding assembly 10c extends along a closed profile 348 surrounding the central region 136 of the glass structure 100. In one embodiment, the first foil-to-glass laser bonding portion 202a extends along the first closed profile 236a, and the second foil-to-glass laser bonding portion 202b extends along the second closed profile 236b. In another embodiment, the first glass-to-glass laser bonding portion 344a extends along the first closed profile 348a, and the second glass-to-glass laser bonding portion 344b extends along the second closed profile 348b.

[0090] Now for reference Figure 3 and Figure 11 Although the first foil-glass laser bonding portion 202a and the first glass-glass laser bonding portion 344a are spaced apart from each other in the thickness direction, as Figure 3 As shown in the cross-section, but these laser-bonded portions are depicted as... Figure 11 In the top view, it extends along a single closed profile (e.g., the closed profile associated with reference numerals 236, 236a, 348, 348a) because all these laser-bonded portions are substantially laterally aligned with each other, as... Figure 3 As shown in the diagram, the second foil-glass laser bonding portion 202b and the second foil-glass laser bonding portion 202b are arranged laterally outward from the first foil-glass laser bonding portion 202a and the first glass-glass laser bonding portion 344a, and the first foil-glass laser bonding portion 202a and the first glass-glass laser bonding portion 344a, respectively, along their extended second closed contour 236b. The second glass-glass laser bonding portion 344b and the second glass-glass laser bonding portion 344b are arranged laterally inward from the first foil-glass laser bonding portion 202a and the first glass-glass laser bonding portion 344a, and the first foil-glass laser bonding portion 202a and the first glass-glass laser bonding portion 344a, respectively, along their extended second closed contour 348b.

[0091] In an embodiment, the first foil-glass laser bond portion 202a and the second foil-glass laser bond portion 202b of the third laser bonding assembly 10c can be formed using the same or substantially the same laser beam welding steps used to form the corresponding laser bond portions of the first laser bonding assembly 10a and the second laser bonding assembly 10b. In an embodiment, one or more glass-glass laser bond portions 344 are formed via one or more welding steps, in which a laser beam passes along corresponding contact locations between the glass materials of different components or parts of the third laser bonding assembly 10c to facilitate line bonding between the glass materials.

[0092] Additionally, the laser beam can pass through the third contact location to facilitate line bonding between the first cover glass 300 and the second main surface 116 of the glass structure 100 (e.g., along the first glass-to-glass laser bonding portion 344a of the first closed profile 348a). In an embodiment, the first glass-to-glass laser bonding portion 344a may have a fifth bonding width t5 greater than or equal to 5 μm and less than or equal to 100 μm. Furthermore, the laser beam can surround the inner periphery 228 of the metal foil 250, such that the first glass-to-glass laser bonding portion 344a between the first cover glass 300 and the second main surface 116 surrounds the inner periphery 228 of the metal foil 250.

[0093] A laser beam can pass through a fourth contact location to facilitate line bonding between the second cover glass 320 and the first main surface 108 of the glass structure 100 (e.g., a second glass-glass laser bond 344b along a second closed profile 348b). In an embodiment, the second glass-glass laser bond 344b may have a sixth bonding width t6 greater than or equal to 5 μm and less than or equal to 100 μm. Furthermore, the laser beam can pass laterally inward from the inner periphery 228 of the metal foil 250, such that the second glass-glass laser bond 344b between the second cover glass 320 and the first main surface 108 is positioned laterally inward from the inner periphery 228 of the metal foil 250.

[0094] The fixtures and processes (including laser parameters) for forming one or more foil-glass laser bonding portions 202 and / or foil-to-foil laser bonding portions 220 to hermetically seal the glass structure 100 of the second laser bonding assembly 10b and connect the glass structure 100 to the first cover glass 300 and / or the second cover glass 320 of the second laser bonding assembly 10b can be used to form one or more foil-glass laser bonding portions 202 and / or one or more glass-to-glass laser bonding portions 344 to hermetically seal the glass structure 100 of the third laser bonding assembly 10c and connect the glass structure 100 to the first cover glass 300 and the second cover glass 320 of the third laser bonding assembly 10c.

[0095] In an exemplary embodiment, Figure 3 and Figure 11 The positioning of one or more foil-to-glass laser bond portions 202 and one or more glass-to-glass laser bond portions 344 in the third laser bonding assembly 10c shown enables the formation of one or more foil-to-glass laser bond portions 202 and one or more glass-to-glass laser bond portions 344 in a single laser beam welding step, without the need for unloading, flipping, reloading, and realigning the glass structure 100 as might be required in other configurations. A single laser beam welding step can be used in a configuration of the laser bonding assembly where the second cover glass 320 and the second glass-to-glass laser bond portion 344b are omitted from the third laser bonding assembly 10c.

[0096] Now for reference Figure 4 The diagram illustrates a laser bonding assembly 10d in a fourth configuration. For ease of description, the laser bonding assembly 10a in the fourth configuration may be interchangeably referred to as the fourth laser bonding assembly 10d, but such reference should not be construed as limiting the scope of this disclosure. The fourth laser bonding assembly 10d includes some elements that are the same as or substantially similar to those of the first laser bonding assembly 10a, the second laser bonding assembly 10b, and / or the third laser bonding assembly 10c. Elements of the fourth laser bonding assembly 10d that are the same as or substantially similar to those of the first laser bonding assembly 10a, the second laser bonding assembly 10b, and / or the third laser bonding assembly 10c (e.g., in terms of structure, material, characteristics, manufacturing process, etc.) are identified using the same reference numerals. New or different elements of the fourth laser bonding assembly 10d are identified using unique reference numerals.

[0097] The fourth laser bonding assembly 10d includes a glass structure 100 as described above. The glass structure 100 is configured to be hermetically sealed (e.g., by a separate polymer seal or a polymer seal combined with other components). The glass structure 100 includes a first glass substrate 104 and a second glass substrate 112 defining a first main surface 108 and a second main surface 116, respectively. Optionally, the glass structure 100 of the fourth laser bonding assembly 10b includes a filler layer 118 as described above with reference to the first laser bonding assembly 10a, the second laser bonding assembly 10b, and the third laser bonding assembly 10c. The glass structure 100 further includes a peripheral edge 120 extending between the first main surface 108 and the second main surface 112 surrounding a periphery 124 of the glass structure 100.

[0098] Still referencing Figure 4The fourth laser bonding assembly 10d further includes a polymer seal 500 configured to surround the peripheral edge 120 of the glass structure 100. As used herein, the terms "encircle," "encircles," etc., mean when... Figure 4 As indicated by arrow 504, when viewed from a position laterally outside or external to the glass structure 100 and the polymer seal 500 in a direction parallel to the first main surface 108 and the second main surface 116, the polymer seal 500 is shaped and / or positioned to encompass, surround, and / or cover the entire peripheral edge 120 (e.g., a surface that forms or defines the peripheral edge). In embodiments, the polymer seal 500 may comprise any polymer or polymer-based material capable of achieving the geometry, properties, attributes, performance, and / or function described throughout this disclosure with respect to the polymer seal 500.

[0099] The fourth laser bonding assembly 10d further includes a first cover glass 350 and a second cover glass 370. The first cover glass 350 includes a first inner surface 352 and a first outer surface 354 opposite to the first inner surface 352. The second cover glass 370 includes a second inner surface 372 and a second outer surface 374 opposite to the first inner surface 372. The first cover glass 350 is disposed adjacent to the polymer seal 500 and the glass structure 100 on a first side (e.g., the top side) of the fourth laser bonding assembly 10d. The second cover glass 370 is disposed adjacent to the polymer seal 500 and the glass structure 100 on a second side (e.g., the bottom side) of the fourth laser bonding assembly 10d opposite to the first cover glass 350. The glass structure 100 and the polymer seal 500 are disposed between the first cover glass 350 and the second cover glass 370 and / or in a cavity 378 surrounded by the first cover glass 350 and the second cover glass 370.

[0100] In an embodiment, the first cover glass 350 of the fourth laser bonding assembly 10d may be the same as or substantially similar to the first cover glass 300 of the third laser bonding assembly 10c in terms of material and / or properties. The second cover glass 370 of the fourth laser bonding assembly 10d may be the same as or substantially similar to the first cover glass 350 of the fourth laser bonding assembly 10d in terms of structure, material and / or properties, or the second cover glass 370 may be different from the first cover glass 350 in terms of structure, material and / or properties.

[0101] In an embodiment, at least one of the first cover glass 350 and the second cover glass 370 includes a peripheral wall 382 that extends around its periphery toward the other of the first cover glass 350 and the second cover glass 370 and at least partially defines a cavity 378. Figure 4In the illustrated embodiment, the first cover glass 350 includes a peripheral wall 382 extending toward the second cover glass 370. In another embodiment, the second cover glass 370 may include a peripheral wall (not shown) extending toward the first cover glass 350. In yet another embodiment, each of the first cover glass 350 and the second cover glass 370 may include a corresponding peripheral wall (or peripheral wall portion) extending toward the other of the first cover glass 350 and the second cover glass 370. For example, the first cover glass 350 may include a first peripheral wall extending toward the second cover glass 370, and the second cover glass 370 may include a second peripheral wall extending toward the first cover glass 350.

[0102] In embodiments including a first peripheral wall and a second peripheral wall, the length of the first peripheral wall (e.g., in the direction in which the peripheral wall extends) may be the same as or substantially similar to the length of the second peripheral wall. In embodiments including a first peripheral wall and a second peripheral wall, the length of the first peripheral wall (e.g., in the direction in which the peripheral wall extends) may be different from the length of the second peripheral wall.

[0103] In an embodiment, the second cover glass 370 is connected to one or more of the glass structure 100 and the first cover glass 350 via one or more glass-to-glass laser bonding portions 394. As used herein, "glass-to-glass laser bonding portion" refers to a mechanical connection (directly) established between the glass material (e.g., glass or glass-ceramic) of the (first) component or part of the fourth laser bonding assembly 10d and the glass material of at least the (second) component or part of the fourth laser bonding assembly 10d, and formed via a laser beam directed near the contact location between the glass materials of the (first and second) components.

[0104] In an embodiment, the first cover glass 350 and the second cover glass 370 are connected to each other at the peripheral wall 382 via a first glass-to-glass laser bond 394a in one or more glass-to-glass laser bond portions 394. For example, as Figure 4As shown, the first cover glass 350 and the second cover glass 370 can be connected at a first contact position between the end surface 386 of the peripheral wall 382 of the first cover glass 350 and the second inner surface 372 of the second cover glass 370 via a first glass-glass laser bonding portion 394a. In embodiments where the second cover glass 370 has a peripheral wall (not shown) and the first cover glass 350 does not have a peripheral wall (not shown), the first cover glass 350 and the second cover glass 370 can be connected at a first contact position between the end surface of the peripheral wall of the second cover glass 370 and the second inner surface 352 of the first cover glass 350 via the first glass-glass laser bonding portion. In embodiments where each of the first cover glass 350 and the second cover glass 370 has a peripheral wall (not shown), the first cover glass 350 and the second cover glass 370 can be connected at a first contact position between the end surface of the peripheral wall of the first cover glass 350 and the end surface of the peripheral wall of the second cover glass 370 via the first glass-glass laser bonding portion.

[0105] In one embodiment, the second cover glass 370 is connected to the first main surface 108 of the glass structure 100 (e.g., at a second contact location) via a second glass-to-glass laser bond 394b of one or more glass-to-glass laser bond portions 394. In another embodiment, the first cover glass 350 is connected to the second main surface 116 of the glass structure 100 (e.g., at a third contact location) via a third glass-to-glass laser bond 394c of one or more glass-to-glass laser bond portions 394. In another embodiment, the second cover glass 370 is additionally or alternatively connected to the first main surface 108 of the glass structure 100 at the second contact location via an optically clear adhesive (OCA). In another embodiment, the first cover glass 350 is additionally or alternatively connected to the second main surface 116 of the glass structure 100 at the third contact location via an optically clear adhesive (OCA).

[0106] In one embodiment, the first main surface 108 of the first glass substrate 104 substantially abuts the second inner surface 372 of the second cover glass 370 along which the second glass-to-glass laser bonding portion 394b is formed, such that the second contact position can be positioned along any portion of the first main surface 108. In another embodiment, the second main surface 116 of the second glass substrate 112 substantially abuts the first inner surface 352 of the first cover glass 350 along which the first glass-to-glass laser bonding portion 344a is formed, such that the third contact position can be positioned along any portion of the second main surface 116.

[0107] Still referencing Figure 4The first cover glass 350 and the second cover glass 370 are disposed adjacent to the glass structure 100 and the polymer seal 500 on opposite sides, such that the glass structure 100 and the polymer seal 500 are positioned between the first cover glass 350 and the second cover glass 370. In an embodiment, the polymer seal 500 abuts the peripheral edge 120 of the glass structure 100 around the periphery 124 of the glass structure 100. For example, during the manufacture of the fourth laser bonding assembly 10d, the polymer seal 500 may be disposed directly against the peripheral edge 120 of the glass structure 100.

[0108] In embodiments, the polymer seal 500 may be configured as a flexible or semi-flexible centrally open member, which is configured to be stretched and positioned onto one or more of the periphery 124 of the glass structure 100. In such embodiments, the polymer seal 500 may have any shape (e.g., circular, rectangular, triangular, freeform, etc.) configured to conform to the periphery 124 of the glass structure when placed on the glass structure 100. In embodiments, the polymer seal 500 may be configured as a rigid, semi-rigid, or flexible member positioned, applied, and / or deposited onto and near the peripheral edge 120 around the entire periphery 124 of the glass structure 100. In embodiments, the laterally inward side 508 of the polymer seal 500 is configured to abut the peripheral edge 120 of the glass structure 100. In embodiments, the laterally outward side 512 of the polymer seal 500 (e.g., opposite to the laterally inward side 508) is exposed within a portion of the cavity 378 not occupied by other features of the glass structure 100 or the fourth laser bonding assembly 10d.

[0109] In an embodiment, the upper and lower sides of the polymer seal 500 abut against the opposing inner surfaces of the first and second cover glasses. For example, when the first cover glass 350 and the second cover glass 370 are joined via the first glass-to-glass laser bonding portion 349a, the upper side 516 of the polymer seal 500 abuts against the lower side 520 of the first inner surface 352 of the first cover glass 350 and the second inner surface 372 of the second cover glass 370. In an embodiment, during the manufacture of the fourth laser bonding assembly 10d, the first thickness of the polymer seal 500 in the thickness direction between the upper side 516 and the lower side 520 may be greater than the thickness of the glass structure 100 and its peripheral edge 120 in the thickness direction, such that when the first cover glass 350 and the second cover glass 370 are joined together via the first glass-to-glass laser bonding portion 394a, the polymer seal 500 is compressed to a second thickness (e.g., less than the first thickness) between the first cover glass 350 and the second cover glass 370.

[0110] Now for reference Figure 12 , showing Figure 4A simplified schematic top view of the fourth laser bonding assembly 10d, to show aspects of one or more glass-to-glass laser bonding portions 394. Figure 12 The view is simplified because most features of the fourth laser bonding assembly 10d are shown as completely transparent. For simplicity, the periphery 124 of the glass structure 100, the laterally inward side 508 of the polymer seal 500 (which coincides with the periphery 124 of the glass structure 100), the laterally outward side 512 of the polymer seal 500, and the inward edge 390 of the peripheral wall 382 are depicted using dashed lines because these features are... Figure 12 The glass is positioned below the first cover glass 300 in the view. One or more glass-to-glass laser bonding sections 394 are depicted using bold lines to emphasize their general structure.

[0111] like Figure 12 As shown, each of one or more glass-to-glass laser bonding portions 394 (e.g., a first glass-to-glass laser bonding portion 394a, a second glass-to-glass laser bonding portion 394b, and a third glass-to-glass laser bonding portion 394c) of the fourth laser bonding assembly 10d extends along a corresponding closed profile 396 surrounding the central region 136 of the glass structure 100. In an embodiment, the first glass-to-glass laser bonding portion 394a extends along a first closed profile 396a, the second glass-to-glass laser bonding portion 394b extends along a second closed profile 396b, and the third glass-to-glass laser bonding portion 394c extends along a third closed profile 396c.

[0112] Now for reference Figure 4 and Figure 12 Each of the glass-to-glass laser bonding portions 394 in the fourth laser bonding assembly 10d is laterally spaced from each other. In an embodiment, the first glass-to-glass laser bonding portion 394a (shown as along) Figure 12 The first closed profile 396a extends from the second glass-to-glass laser bonding portion 394b (shown as along the first closed profile 396a). Figure 12 The second closed profile 396b extends from the third glass-to-glass laser bonding portion 349c (shown as along the second closed profile 396b). Figure 12The third closed contour 396c extends laterally outward. In one embodiment, the third glass-to-glass laser bond 394c is laterally inward from the first glass-to-glass laser bond 394a and the second glass-to-glass laser bond 394b. In another embodiment, the second glass-to-glass laser bond 394b is disposed between the first glass-to-glass laser bond 394a and the third glass-to-glass laser bond 394c, such that the second glass-to-glass laser bond 394b is laterally inward from the first glass-to-glass laser bond 394a. In such embodiments, the second glass-to-glass laser bond 394b is also laterally outward from the third glass-to-glass laser bond 394c.

[0113] In embodiments, the first glass-to-glass laser bond portion 394a, the second glass-to-glass laser bond portion 394b, and the third glass-to-glass laser bond portion 394c of the fourth laser bonding assembly 10d can be formed using the same or substantially the same laser beam welding steps used to form the glass-to-glass laser bond portion 344 of the third laser bonding assembly 10c. For example, one or more glass-to-glass laser bonds 394 are formed via one or more welding steps in which a laser beam passes along corresponding contact locations between the glass materials of different components or parts of the fourth laser bonding assembly 10d to facilitate line bonding between the glass materials (e.g., the first glass-to-glass laser bond portion 394a along a first closed profile 396a, the second glass-to-glass laser bond portion 394b along a second closed profile 396b, and the third glass-to-glass laser bond portion 394c along a third closed profile 396c). Figure 12 As shown, the first glass-to-glass laser bonding portion 394a may have a first bonding width t1, the second glass-to-glass laser bonding portion 394b may have a second bonding width t2, and the third glass-to-glass laser bonding portion 394c may have a third bonding width t3. In an embodiment, each of the first bonding width t1, the second bonding width t2, and the third bonding width t3 may be greater than or equal to 5 μm and less than or equal to 100 μm.

[0114] The fixtures and processes (including laser parameters) for forming one or more foil-to-glass laser bonding portions 202, foil-to-foil laser bonding portions 220, and glass-to-glass laser bonding portions 344 to hermetically seal the glass structure 100 of the third laser bonding assembly 10c and to connect the glass structure 100 to the first cover glass 300 and / or the second cover glass 320 of the third laser bonding assembly 10c can be used to form one or more glass-to-glass laser bonding portions 394 to hermetically seal the glass structure 100 of the fourth laser bonding assembly 10d and to connect the glass structure 100 to the first cover glass 350 and the second cover glass 370 of the fourth laser bonding assembly 10d.

[0115] This document describes an exemplary method for forming a fourth laser-bonded assembly 10d. The method includes the following steps: laser-bonding a first primary surface 108 of a glass structure 100 to a second inner surface 372 of a second cover glass 370 via a second glass-to-glass laser bonding portion 394b. Next, a polymer seal 500 is disposed on the second inner surface 372 of the second cover glass 370 to surround the glass structure 100 (e.g., a glass structure including a first glass substrate 104, a second glass substrate 112, and a filler layer 118). In embodiments, the polymer seal 500 may be applied and / or mounted as a single component (e.g., an O-ring), or the polymer seal 500 may be applied in a liquid or semi-liquid form and then cured into a solid or semi-solid form. In embodiments where the polymer seal 500 is configured to be applied and then cured, a first cover glass 350 is positioned on the second cover glass 370 prior to curing the polymer seal 500.

[0116] After curing the polymer seal 500, the method includes the step of laser welding a first cover glass 350 to a second cover glass 370 via a first glass-to-glass laser bonding portion 394a. In embodiments where the thickness of the polymer seal 500 is greater than the thickness between the inner surfaces of the first and second cover glasses when they are joined, the thickness difference causes compression on the polymer seal 500, thereby enhancing the seal of the glass structure 100. Optionally, depending on the required integrity of the hermetic seal of the glass structure 100, the first inner surface 352 of the first cover glass 350 may be laser welded to the second main surface 116 of the second glass substrate 112 of the glass structure via a third glass-to-glass laser bonding portion 394c. In embodiments, the laser welding used to form the second glass-to-glass laser bonding portion 394b and the third glass-to-glass laser bonding portion 394c should be sufficiently distanced from the polymer seal 500 to prevent damage to the polymer seal 500 due to the (high) temperature during laser welding.

[0117] Now for reference Figure 5 The diagram illustrates a laser bonding assembly 10e in a fifth configuration. For ease of description, the laser bonding assembly 10e in the fifth configuration may be interchangeably referred to as the fifth laser bonding assembly 10e, but such reference should not be construed as limiting the scope of this disclosure. The fifth laser bonding assembly 10e includes some elements that are the same as or substantially similar to those of the fourth laser bonding assembly 10d. Elements of the fifth laser bonding assembly 10e that are the same as or substantially similar to those of the fourth laser bonding assembly 10d (e.g., in terms of structure, material, characteristics, manufacturing process, etc.) are identified using the same reference numerals. New or different elements of the fifth laser bonding assembly 10e are identified using unique reference numerals.

[0118] The fifth laser bonding assembly 10e includes a glass structure 100, a first cover glass 350, and a second cover glass 370 as described above with reference to the fourth laser bonding assembly 10d. In an embodiment, the glass structure 100 of the fifth laser bonding assembly 10e is configured to be hermetically sealed by one or more of the first cover glass 350, the second cover glass 370, and a polymer seal 550. The glass structure 100 includes a first glass substrate 104 and a second glass substrate 112 defining a first main surface 108 and a second main surface 116, respectively. The glass structure 100 of the fifth laser bonding assembly 10e optionally includes a filler layer 118 as described above with reference to the first laser bonding assemblies 10a, the second laser bonding assembly 10b, the third laser bonding assembly 10c, and the fourth laser bonding assembly 10d. The glass structure 100 further includes a peripheral edge 120 extending between the first main surface 108 and the second main surface 112 surrounding a periphery 124 of the glass structure 100.

[0119] In an embodiment, the polymer seal 550 of the fifth laser bonding assembly 10e may be configured as a flexible or semi-flexible centrally open member, the centrally open member being configured to be stretched and positioned onto one or more of the periphery 124 of the glass structure 100. In such embodiments, the polymer seal 550 may have any shape (e.g., circular, rectangular, triangular, freeform, etc.) configured to conform to the periphery 124 of the glass structure when placed on the glass structure 100. In an embodiment, the polymer seal 550 may be configured as a rigid, semi-rigid, or flexible member positioned, applied, and / or deposited onto and near the peripheral edge 120 around the entire periphery 124 of the glass structure 100. In an embodiment, the laterally inward side 558 of the polymer seal 550 of the fifth laser bonding assembly 10e is configured to abut the peripheral edge 120 of the glass structure 100.

[0120] In an embodiment, the upper and lower sides of the polymer seal 550 of the fifth laser bonding assembly 10e abut against the opposing inner surfaces of the first and second cover glasses. For example, when the first cover glass 350 and the second cover glass 370 are joined via the first glass-to-glass laser bonding portion 349a, the upper side 566 of the polymer seal 550 abuts against the lower side 570 of the first inner surface 352 of the first cover glass 350 and the second inner surface 372 of the second cover glass 370. In an embodiment, during the manufacture of the fifth laser bonding assembly 10e, the first thickness of the polymer seal 550 in the thickness direction between the upper side 566 and the lower side 570 may be greater than the thickness of the glass structure 100 and its peripheral edge 120 in the thickness direction, such that when the first cover glass 350 and the second cover glass 370 are joined together via the first glass-to-glass laser bonding portion 394a, the polymer seal 550 is compressed to a second thickness (e.g., less than the first thickness) between the first cover glass 350 and the second cover glass 370.

[0121] Now for reference Figure 4 and Figure 5 The polymer seal 550 of the fifth laser bonding assembly 10e is structurally different from the polymer seal 500 of the fourth laser bonding assembly 10d. In an embodiment, as... Figure 5 As shown, the polymer seal 550 of the fifth laser bonding assembly 10e is configured to fill the cavity 378 surrounded by the glass structure 100 and the inner surfaces 352, 372 of the first cover glass 350 and the second cover glass 370. Figure 4 The entire (empty) space or volume within a portion of the ). For example, the laterally outward side 562 of the polymer seal 550 of the fifth laser bonding assembly 10e is configured to abut the inward edge 390 of the peripheral wall 382. The polymer seal 500 of the fourth laser bonding assembly 10d does not fill the cavity 378, thus preserving a (empty) space or volume therein, as referenced above. Figure 4 As described. The polymer seal 550 of the fifth laser bonding assembly 10e can enhance the hermetic seal of the glass structure 100 and improve the damping (shock, vibration and / or shock) in the glass structure 100.

[0122] The polymer seal 550 of the fifth laser bonding assembly 10e may be the same as or substantially similar to the polymer seal 500 of the fourth laser bonding assembly 10d in terms of material, properties and / or manufacturing process, or the polymer seal 550 may be different from the polymer seal 500 in terms of material, properties and / or manufacturing process.

[0123] The fixtures and processes (including laser parameters) for forming one or more glass-to-glass laser bonding portions 394 to hermetically seal the glass structure 100 of the fourth laser bonding assembly 10d and to connect the glass structure 100 to the first cover glass 350 and / or the second cover glass 370 of the fourth laser bonding assembly 10d can be used to form one or more glass-to-glass laser bonding portions 394 to hermetically seal the glass structure 100 of the fifth laser bonding assembly 10e and to connect the glass structure 100 to the first cover glass 350 and / or the second cover glass 370 of the fifth laser bonding assembly 10e.

[0124] Now for reference Figure 6 The diagram illustrates a laser bonding assembly 10f in a sixth configuration. For ease of description, the laser bonding assembly 10f in the sixth configuration may be interchangeably referred to as the sixth laser bonding assembly 10f, but such reference should not be construed as limiting the scope of this disclosure. The sixth laser bonding assembly 10f includes a number of elements that are identical or substantially similar to those of the fourth laser bonding assembly 10d and the fifth laser bonding assembly 10e. Elements of the sixth laser bonding assembly 10f that are identical or substantially similar to those of the fourth laser bonding assembly 10d and / or the fifth laser bonding assembly 10e (e.g., in terms of structure, material, characteristics, manufacturing process, etc.) are identified using the same reference numerals.

[0125] Now for reference Figure 5 and Figure 6 The sixth laser bonding assembly 10f is substantially similar to the fifth laser bonding assembly 10e, except that the third glass-to-glass laser bonding portion 394c between the first cover glass 350 and the second main surface 116 of the second glass substrate 112 of the glass structure 100 is omitted in the sixth laser bonding assembly 10f (e.g., Figure 5 (As shown in the diagram). Omitting the third glass-to-glass laser bonding section 394c can reduce the process steps and time required to form the sixth laser bonding assembly 10f without having a foreseeable negative impact on the hermeticity of the glass structure 100.

[0126] The fixtures and processes (including laser parameters) for forming one or more glass-to-glass laser bonding portions 394 to hermetically seal the glass structure 100 of the fifth laser bonding assembly 10e and to connect the glass structure 100 to the first cover glass 350 and / or the second cover glass 370 of the fifth laser bonding assembly 10e can be used to form one or more glass-to-glass laser bonding portions 394 to hermetically seal the glass structure 100 of the sixth laser bonding assembly 10f and to connect the glass structure 100 to the first cover glass 350 and / or the second cover glass 370 of the sixth laser bonding assembly 10f.

[0127] The various embodiments of the laser bonding assemblies 10a, 10b, 10c, 10d, 10e, and 10f disclosed herein have many advantages over existing assemblies or devices that include hermetically sealed glass structures. Specifically, each of the laser bonding assemblies 10a, 10b, 10c, 10d, 10e, and 10f disclosed herein, including at least one cover glass (e.g., a first cover glass 300, 350) and various configurations of the laser bonding portions 202, 220, 344, and / or 394 disclosed herein, can solve some existing problems related to the edge strength and fixation of glass structures used in existing assemblies or devices. Examples of such existing problems are described below for additional context.

[0128] To enable mass production of glass structures, particularly those including filler layers, the filler material can be applied to the glass at the wafer level before the wafer is individually diced into the individual components / devices forming the glass structure. However, (composite) glass structures made of glass and filler (e.g., non-brittle, typically polymeric materials) can be difficult to cut. This difficulty arises because brittle and ductile materials have different effective cutting methods, especially when cutting free-form (non-linear) shapes from (composite) glass structures. Consequently, the edge strength of (composite) glass structures can be lower after cutting compared to glass structures made solely of glass. Furthermore, because filler materials can be environmentally sensitive, performing mechanical edge finishing (e.g., grinding / polishing) after cutting (e.g., after laser cutting) may be impractical.

[0129] Furthermore, stress modeling shows that when the (composite) glass structure is subjected to stress, the two surfaces experiencing the greatest stress are those inside the part. This result can be understood in the context that the filler material is compliant; for example, the filler material is not rigid and therefore can bend to some extent. Due to this compliance, bending can apply more stress to the glass portion of the (composite) glass structure. Additionally, when a metal foil with orifices (e.g., orifices exposing the central region of the glass structure) is positioned / bonded to one or two main surfaces of the glass structure to provide an hermetically tight seal, additional stress points / regions are formed thereon. This stress concentration is a consequence of the metal foil not completely covering the main surfaces of the glass structure.

[0130] These existing edge strength and stress management issues can make it difficult to manufacture hermetically sealed glass structures that meet durability and hermeticity requirements. For most consumer electronics applications, edges must be pristine; otherwise, the item may not withstand the impacts and stresses of normal use. In the case of composite glass structures including filler layers, edge strength may decrease after cutting, and correcting this decrease via post-processing may be impossible, as described above. Therefore, composite glass structures may not be sufficient to pass consumer testing. Additionally, while existing metal foils can be adequately used as hermetic seals, such foils may not be rigid enough to mount / secure the glass structure to other components of the assembly.

[0131] The laser bonding assemblies 10a, 10b, 10c, 10d, 10e, and 10f of this disclosure address the aforementioned prior art and other problems by using at least one cover glass (e.g., a first cover glass 300, 350) configured to separate hermeticity requirements from processing and reliability requirements, such as those for consumer electronics devices. Specifically, the at least one cover glass may undergo ion exchange (e.g., with or without edge finishing) to provide excellent edge strength and scratch resistance. In embodiments of the laser bonding assemblies 10a, 10b, and 10c that include a frame (e.g., formed of metal or a similar rigid material), the at least one cover glass may be mechanically attached to the frame to better handle stress and impact on the glass. The edge quality of the first glass substrate 104 and the second glass substrate 112 of the glass structure 100 used in the laser bonding assemblies 10a, 10b, 10c, 10d, 10e, and 10f disclosed herein may be less critical because the stress on the edges of these assemblies is significantly reduced due to the inclusion of at least one cover glass.

[0132] The fourth laser bonding assembly 10d, the fifth laser bonding assembly 10e, and the sixth laser bonding assembly 10f of this disclosure may have additional advantages. As described above, the metal (e.g., aluminum) of the metal foils 200, 250 used in conjunction with the first laser bonding assembly 10a, the second laser bonding assembly 10b, and the third laser bonding assembly 10c is replaced with a polymer of the polymer seals 500, 550 used in conjunction with the fourth laser bonding assembly 10d, the fifth laser bonding assembly 10e, and the sixth laser bonding assembly 10f. Furthermore, instead of removing the metal of the frames 400, 420 used in conjunction with the first laser bonding assembly 10a, the second laser bonding assembly 10b, and the third laser bonding assembly 10c, a first (three-dimensionally formed) cover glass (e.g., first cover glass 350) is directly welded to a second cover glass (e.g., second cover glass 370) in the fourth laser bonding assembly 10d, the fifth laser bonding assembly 10e, and the sixth laser bonding assembly 10f. The hermetic-sealed glass structure 100 disclosed herein now incorporates laser welding and polymers, which not only enhance hermeticity but also provide the following additional advantages.

[0133] The advantages associated with using polymers instead of metals (e.g., aluminum) include: solving problems associated with mounting / fixing soft aluminum; solving problems associated with mismatches in the mechanical and thermal properties and CTE between the metal (aluminum) and glass, which can lead to residual stress in the glass; the process of applying and curing polymers is substantially easier, faster, and cheaper than laser welding; polymers can suppress stress waves / vibrations, which can help the integrity and performance of glass structures, especially under dynamic loads (e.g., due to drop and fall); eliminating the foil reduces the complexity and uncertainty of the resulting composition and potential defects (e.g., voids) resulting from the mixing of two different materials (glass and aluminum) in the molten pool; and removing the metal improves corrosion resistance.

[0134] The advantages associated with using a pre-formed cover glass instead of a (metal) frame include: laser welding of the cover glass is advantageous compared to mechanical attachment to a metal frame, taking into account airtightness, and the glass structure can be lighter.

[0135] While the present disclosure has been shown and described in detail in the accompanying drawings and the foregoing description, these drawings and description should be considered illustrative and non-limiting. It should be understood that only preferred embodiments have been presented, and protection is intended for all changes, modifications, and further applications that appear within the spirit of this disclosure.

Claims

1. A laser bonding assembly, the laser bonding assembly comprising: A glass structure comprising: (i) a first glass substrate defining a first main surface; (ii) a second glass substrate disposed adjacent to the first glass substrate and defining a second main surface opposite to the first main surface; and (iii) a peripheral edge extending between the first main surface and the second main surface around the periphery of the glass structure. A metal foil surrounding the periphery of the glass structure, the metal foil being connected to the glass structure via one or more foil-glass laser bonding portions; A first cover glass, the first cover glass being connected to one or more of the glass structure or the metal foil; and A frame is disposed adjacent to the first cover glass, and the glass structure and the metal foil are at least partially surrounded by the frame and the first cover glass.

2. The laser bonding assembly of claim 1, wherein the metal foil includes a first foil portion extending toward the glass structure and connected to the first main surface at a first contact location.

3. The laser bonding assembly of claim 1, wherein the first foil portion includes a first foil surface, the first foil surface being connected to the first main surface at the first contact location via a first foil-glass laser bonding portion in one or more foil-glass laser bonding portions.

4. The laser bonding assembly of claim 1, wherein the metal foil includes a second foil portion extending toward the glass structure and connected to the second main surface at a second contact location.

5. The laser bonding assembly of claim 4, wherein the second foil portion includes a second foil surface, the second foil surface being connected to the second main surface at the second contact location via a second foil-glass laser bonding portion in one or more foil-glass laser bonding portions.

6. The laser bonding assembly of claim 5, wherein the second foil portion is connected to the first cover glass at the third contact position.

7. The laser bonding assembly of claim 6, wherein the second foil portion includes a third foil surface, the third foil surface being connected to the first cover glass at the third contact location via a third foil-glass laser bonding portion of the one or more foil-glass laser bonding portions.

8. The laser bonding assembly of claim 6, wherein the second foil portion includes a third foil surface, the third foil surface being attached to the first cover glass at the third contact location via an optically transparent adhesive.

9. The laser bonding assembly of claim 4, further comprising a second cover glass adjacent to the frame and disposed opposite to the first cover glass, the glass structure and the metal foil disposed between the first cover glass and the second cover glass.

10. The laser bonding assembly of claim 9, wherein the first foil portion is connected to the second cover glass at the fourth contact position.

11. The laser bonding assembly of claim 10, wherein the first foil portion includes a fourth foil surface, the fourth foil surface being connected to the second cover glass at the fourth contact location via a fourth foil-glass laser bonding portion of the one or more foil-glass laser bonding portions.

12. The laser bonding assembly of claim 1, wherein the metal foil includes a second foil portion extending away from the glass structure and connected to the first cover glass at a second contact location.

13. The laser bonding assembly of claim 12, wherein the second foil portion includes a second foil surface, the second foil surface being connected to the first cover glass at the second contact location via a second foil-glass laser bonding portion in one or more foil-glass laser bonding portions.

14. The laser bonding assembly of claim 12, wherein the first cover glass is connected to the second main surface of the glass structure via a first glass-to-glass laser bonding portion.

15. The laser bonding assembly of claim 14, wherein the first glass-glass laser bonding portion is disposed in one or more of the following ways: (i) laterally inward from the second foil-glass laser bonding portion, or (ii) substantially laterally aligned with the first foil-glass laser bonding portion.

16. The laser bonding assembly of claim 14, further comprising a second cover glass disposed adjacent to the frame and opposite to the first cover glass, the glass structure and the metal foil disposed between the first cover glass and the second cover glass.

17. The laser bonding assembly of claim 16, wherein the second cover glass is connected to the first main surface of the glass structure via a second glass-to-glass laser bonding portion.

18. The laser bonding assembly of claim 17, wherein the second glass-glass laser bonding portion is disposed laterally inward from one or more of the first glass-glass laser bonding portion, the first foil-glass laser bonding portion, and the second foil-glass laser bonding portion.

19. The laser bonding assembly of claim 1, wherein each of the one or more foil-glass laser bonding portions extends along a corresponding closed profile surrounding a central region of the glass structure.

20. The laser bonding assembly of claim 1, wherein the first cover glass is reinforced.

21. The laser bonding assembly of claim 20, wherein the first cover glass is chemically strengthened via ion exchange.

22. A laser bonding assembly, the laser bonding assembly comprising: A glass structure comprising: (i) a first glass substrate defining a first main surface; (ii) a second glass substrate disposed adjacent to the first glass substrate and defining a second main surface opposite to the first main surface; and (iii) a peripheral edge extending between the first main surface and the second main surface around the periphery of the glass structure. A polymer seal that surrounds the peripheral edge of the glass structure; A first cover glass, the first cover glass being disposed adjacent to the polymer seal and the glass structure; and A second cover glass is disposed adjacent to and opposite the polymer seal and the glass structure, and the glass structure and the polymer seal are disposed in the cavity between the first cover glass and the second cover glass. The second cover glass is connected to the glass structure or one or more of the first cover glass via one or more glass-to-glass laser bonding devices.

23. The laser bonding assembly of claim 22, wherein the polymer seal is adjacent to the peripheral edge of the glass structure.

24. The laser bonding assembly of claim 22, wherein the polymer seal is adjacent to the opposing inner surfaces of the first cover glass and the second cover glass.

25. The laser bonding assembly of claim 22, wherein at least one of the first cover glass or the second cover glass includes a peripheral wall extending toward the other of the first cover glass and the second cover glass, and at least partially defines the cavity.

26. The laser bonding assembly of claim 25, wherein the first cover glass and the second cover glass are connected to each other at the peripheral wall via a first glass-to-glass laser bonding portion of the one or more glass-to-glass laser bonding portions.

27. The laser bonding assembly of claim 26, wherein the second cover glass is connected to the first main surface of the glass structure via a second glass-to-glass laser bonding portion of the one or more glass-to-glass laser bonding portions.

28. The laser bonding assembly of claim 27, wherein the second glass-glass laser bonding portion is disposed laterally inward from the first glass-glass laser bonding portion.

29. The laser bonding assembly of claim 27, wherein the first cover glass is connected to the second main surface of the glass structure via a third glass-to-glass laser bonding portion of the one or more glass-to-glass laser bonding portions.

30. The laser bonding assembly of claim 22, wherein the polymer seal fills the entire void volume between the glass structure and the cavity between the first cover glass and the second cover glass.

31. The laser bonding assembly of claim 22, wherein each of the one or more glass-to-glass laser bonding portions extends along a corresponding closed profile surrounding a central region of the glass structure.

32. The laser bonding assembly of claim 22, wherein one or more of the first cover glass or the second cover glass is strengthened.

33. The laser bonding assembly of claim 32, wherein one or more of the first cover glass or the second cover glass are chemically strengthened via ion exchange.

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