Parallel hermetic seal and assembly including same

Abstract

The vacuum glazing assembly includes first and second spaced apart substrates connected together by a sealing element to form a vacuum interior space therebetween. The sealing element is formed by joining a metal bridge element to at least one of the substrates by cold welding. The cold welding includes at least two spaced apart, high-tight sealing elements that are simultaneously created during joining to at least one of the substrates.

Description

[Technical Field]

[0001] STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT This invention was made with government support under SBIR Support Agreement DE-SC0017841 awarded by the U.S. Department of Energy. The government has certain rights in this invention.

[0002] REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 387,470 (filed December 14, 2022), the entire contents of which are incorporated herein by reference. FIELD OF THE INVENTION The present invention relates to a process for making a hermetic seal including multiple parallel seals for an envelope having an interior region isolated from the environment. [Background technology]

[0003] background Many existing vacuum glazing assemblies (e.g., vacuum insulated glass (“VIG”) assemblies) include two or more glass panes (e.g., panes) separated from each other by a space. Temperature differences between the assemblies can significantly affect the structure of the assembly and, in some cases, cause the assembly to fail. For example, when a vacuum glazing assembly is installed on the exterior wall of a temperature-controlled and / or insulated building, the temperature of the exterior glass panes typically approaches the outside air temperature (contracting when exposed to cold and expanding when exposed to heat). The interior panel typically remains at a relatively constant temperature that matches the interior air temperature. Movement (i.e., contraction or expansion) of the exterior panel relative to the interior panel is known as “differential panel movement.” In VIGs fabricated using rigid edge seal materials, such as solder glass, differential panel movement will result in increased stress in the seal material. Excessive differential panel movement will cause the rigid seal to lose its tightness, for example, by cracking or by partially peeling off from the glass panel, thereby reducing the VIG's ability to isolate due to loss of vacuum.

[0004] The most widely used existing vacuum glazing unit designs use sealing elements incorporating solder glass to connect non-metallized glass panel edges (e.g., Collins, US5657607). More recent vacuum glazing unit designs use sealing elements incorporating brazing metal to connect metallized glass panel edges (e.g., Li, US8899472; Caliaro, WO2017174349Al). Both of these design approaches require the use of ovens to melt the sealing material, which typically requires heating / cooling cycles that take several hours. The long cycle times in oven-based processes present an insurmountable barrier to achieving low manufacturing costs.

[0005] Other existing vacuum glazing units use sealing elements that incorporate oven-free metallization of the glass panel edges. The metallization is achieved using physical vapor deposition (PVD) or chemical vapor deposition (CVD) processes. Such metallization processes require the use of a vacuum chamber to form a metallic adhesive layer that is incorporated into the oven-free sealing element, such as low-temperature solder (e.g., Bachli, US5227206) or ultrasonic welding of metal foil (e.g., Friedl, US20080245011). The large capital and operating costs required by vacuum chamber-based processes, along with the inherent complexity of the process, are virtually insurmountable barriers to achieving low manufacturing costs. Summary of the Invention

[0006] overview One type of hermetic seal element that can be used to seal between panel sheets of a vacuum glazing assembly includes a metal bridge element (e.g., a metal foil) that is ultrasonically welded to a metal adhesive layer deposited on the panel sheets.

[0007] A process for metallizing a non-metallic substrate (e.g., glass) that is performed without an oven and without a vacuum chamber can be used to create hermetic or non-hermetic seal elements for envelopes (made from glass or another non-metallic substrate) having an interior region to be isolated from the environment. The seal element is formed by a metallized layer on the substrate and a metal bridge element connected to the non-metallic substrate by a metal layer. The seal element is formed under ambient conditions and does not require an oven or vacuum chamber. The process involves subjecting the surface of the substrate to a metal deposition process that does not require an oven or vacuum chamber to form a continuous metal adhesive layer along the perimeter of the region to be isolated from the environment. A bridge element is attached or connected to the metal adhesive layer to form the seal element along the perimeter of the interior region to be isolated from the environment. The present invention provides a seal design that is flexible enough to accommodate differential panel sheet movement. The flexible hermetic seal element allows for the use of tempered or annealed glass and glass panels with sputtered low-emissivity coatings without the damage or destruction caused by the high-temperature seal manufacturing process.

[0008] By producing an enclosure having an interior space isolated from the environment by hermetic sealing elements, migration of harmful gases into and out of the isolated space is virtually eliminated. Large, flat, hermetically sealed glass enclosures can be used as fog-free multi-panel argon-filled isolation glass units for windows, vacuum insulated glass units, flat panel displays, neutron detector panels for detecting nuclear material, and packaging for microelectromechanical systems (MEMS), among other applications.

[0009] The sealing element may be formed using a friction surface treatment that produces a metallic adhesive coating on a non-metallic substrate. A metal foil bridge element connects to the metallic adhesive coatings on the two opposing substrates using a process that does not require an oven or vacuum chamber (e.g., low-temperature solder or ultrasonic welding). Although a vacuum chamber is not required, the sealing element can optionally be completed at atmospheric pressure or under vacuum conditions.

[0010] A structural element for a building can have at least two spaced apart non-metallic substrates connected to one another by a sealing element to form an evacuable gap therebetween. The sealing element is formed by subjecting at least one surface of each of the non-metallic substrates to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on each of the substrates. The metal layer defines a continuous coating along the perimeter of the evacuable gap. A metal bridge element is connected to the metal layer to form a seal for the evacuable gap. The seal can be hermetic or non-hermetic.

[0011] A method for manufacturing a structural element including substantially conformally shaped first and second substrates includes forming a sealing element between the substrates to define an evacuable gap. The sealing element is formed by subjecting at least one surface of each substrate to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on the substrate. The metal layer defines a continuous coating along the periphery of the evacuable gap. A bridge element is connected to the metal layer to define a hermetic or non-hermetic seal of the evacuable gap.

[0012] The isolating glass unit can include a first flat panel element, a second flat panel element, and a plurality of spacers disposed between the first and second flat panel elements to space the first flat panel element from the second flat panel element. The unit also includes a sealing element connecting the first and second flat panel elements to form an evacuable gap therebetween. The sealing element is formed by subjecting at least one surface of each substrate to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on each substrate. The metal layer defines a continuous coating along the perimeter of the evacuable gap, and a bridge element is connected to the metal layer to form a hermetic or non-hermetic seal of the evacuable gap.

[0013] A method for manufacturing a structural element including a substrate defining an interior space includes forming a sealing element to surround the interior space and define an evacuable gap. The sealing element is formed by subjecting a surface of the substrate to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on the substrate. The metal layer defines a continuous coating along the periphery of the interior space. A bridge element is connected to the metal layer and extends across the interior space to define a seal for the evacuable gap.

[0014] A process for creating a sealing element for incorporation into an envelope having an environmentally isolated interior region may include subjecting a surface of a wall element to an oven-free and vacuum chamber-free metal deposition process to form a metal layer that extends continuously along the periphery of the environmentally isolated interior region, and connecting a bridge element to the metal layer to form the sealing element along the periphery of the interior region.

[0015] A method for fabricating a structural element includes subjecting a surface of a non-metallic substrate to an oven-free, vacuum chamber-free metal deposition process that includes a friction surface treatment to form a metal layer on the substrate, the metal layer defining a coating on the substrate, and a metal foil connected to the metal layer.

[0016] The structural element may include a non-metallic substrate having a metal layer on at least a portion of the substrate and formed using a friction surface treatment process, wherein a metal foil is attached to the substrate via the metal layer, and the friction surface treatment process includes subjecting at least one surface of the substrate to an oven-free, vacuum chamber-free metal deposition process.

[0017] A method of manufacturing a structural element includes subjecting a surface of a non-metallic substrate to an oven-free, vacuum chamber-free metal deposition process that includes a friction surface treatment to form a metal layer on at least a portion of the substrate, the metal layer defining a coating on the substrate.

[0018] Non-metallic substrates are typically brittle, and the high loads and temperatures used in conventional friction surface treatments of metallic substrates must be reduced or limited to avoid fracturing the non-metallic substrate or tearing its surface, which could cause leaks. In addition to not requiring an oven or vacuum chamber, an advantage of using friction surface treatments to metallize non-metallic substrates is that oxides (e.g., aluminum oxide) and other reaction-inhibiting contaminants can be significantly reduced or eliminated from the joining surface (e.g., the glass interface with the deposited metal). Prior to the present invention, it was unknown to use or how to apply friction surface treatments to produce metallic coatings on non-metallic substrates (e.g., to form a hermetic seal).

[0019] Metal bridge element hermetic seals can fail (i.e., leak) through a variety of different mechanisms, including micro-leak paths along or imperfect interfaces between the metal bridge element and the glass, defects in the metal bridge element (e.g., scratches, wrinkles, microstructural damage, perforations through or along the edges of the weld, the joint between the separate segments that comprise the metal bridge element, etc.), defects in the glass (e.g., scratches), defects due to uncontrolled process parameter variations (e.g., due to "tramp" metal deposited on the sonotrode), and misalignment of overlapping weld segment ends. While these failure mechanisms can be minimized using tightly controlled manufacturing processes, a need exists for seal configurations that can provide more reliable hermeticity in a cost-effective manner.

[0020] In one aspect, the present invention provides an evacuated glazing assembly having first and second spaced apart substrates connected to one another by a metallic bridge element to form an evacuable interior space therebetween, the metallic bridge element being joined to at least one of the substrates by cold welding to effectively isolate the interior space from the ambient environment.

[0021] In another aspect, the present invention provides a vacuum glazing assembly including a first substrate, a second substrate spaced apart from the first substrate to define an interior space therebetween, and a metal bridge element disposed between the first substrate and the second substrate to isolate the interior space from an ambient environment, the metal bridge element including a cold weld joint between the metal bridge element and the first substrate, the cold weld including two or more tightly sealed continuous parallel seals.

[0022] In another aspect, the present invention provides a method for forming a cold weld element for a hermetic seal between two substrates of an evacuated glazing assembly, the method comprising joining a metallic bridge element to each of the two substrates using a sonotrode shape that forms two or more tightly hermetic continuous parallel seals.

[0023] In one aspect, the invention includes an evacuated glazing assembly having first and second spaced apart substrates connected to one another by a sealing element to form an evacuable interior space therebetween, The sealing element may be formed by joining a metallic bridge element to at least one of the substrates by cold welding.

[0024] In another aspect, the invention includes a method of forming a metallic bridge element for a hermetic seal between two substrates of a vacuum glass assembly, the method including bonding a metallic bridge element to each of the two substrates to form at least two hermetic seal stages, applying a sealing material in at least partial contact with a first of the hermetic seal stages, and curing the sealing material to form a second of the hermetic seal stages.

[0025] In at least one embodiment, joining the metallic bridge element to each of the two substrates is accomplished by cold welding.

[0026] In at least one embodiment, the metallic bridge element material comprises at least one selected from the group consisting of aluminum, titanium, and copper.

[0027] In another aspect, the present invention provides a structural element for a building having at least two spaced apart non-metallic substrates connected to each other by a sealing element and forming an evacuable gap therebetween. The sealing element is formed by subjecting at least one surface of each of the non-metallic substrates to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on each of the substrates. The metal layer on each of the non-metallic substrates can define a continuous coating along the perimeter of the evacuable gap. The sealing element is further formed by connecting a metal bridge element to the metal layer to form a seal of the evacuable gap.

[0028] In some embodiments, the metal deposition process includes a friction surface treatment.

[0029] Other features and aspects of the present invention will become apparent from consideration of the following description and drawings. [Brief explanation of the drawings]

[0030] [Figure 1] FIG. 1 is a cross-sectional view of an exemplary product that includes a substrate that defines an interior space and a sealing element that is bonded to the substrate and isolates the interior space from the ambient environment via a metal adhesive layer and a metal bridge element. [Figure 2] FIG. 2 is a top view of the substrate and metal adhesion layer. [Figure 3A] FIG. 3A is a partial cutaway view of another exemplary product including a first substrate, a second substrate, and a sealing element formed of a metal layer applied to each of the substrates and a bridge element attached to the metal layer. [Figure 3B] FIG. 3B is a partial cross-sectional view of the product of FIG. 3A showing the first and second substrates, the solid weld, the sealing element, and the second weld around the perimeter of the first and second substrates. [Figure 4] FIG. 4 is a block diagram of an exemplary process for fabricating a seal element on one or more substrates defining an interior region configured to be isolated from the environment. [Figure 5A] FIG. 5A is a schematic diagram of a friction surfacing process for applying a malleable metal (e.g., aluminum) to a non-metal (e.g., glass) to define a coating on the substrate that partially forms the sealing element. [Figure 5B] FIG. 5B is a schematic illustration of a frictional surfacing process for applying a malleable metal (e.g., aluminum) to a non-metal (e.g., glass) to define a coating on the substrate that partially forms the sealing element, with the mechatrode angled relative to the substrate. [Figure 6] FIG. 6 is a schematic diagram of a solid-state process for welding a metal bridge element to the coating of FIG. 5 to form a sealing element. [Figure 7A] FIG. 7A is a micrograph of an imperforate coating formed using a friction surface treatment. [Figure 7B]FIG. 7B is a micrograph of the imperforate coating of FIG. 7A with a metal foil welded to the coating that defines a sealing element. [Figure 8] FIG. 8 is a schematic diagram of the bond between a metal layer and a substrate, and a metal oxide layer formed on the metal layer. [Figure 9] FIG. 9 is a block diagram of an exemplary process for applying a metal layer or coating onto one or more substrates that can be incorporated into a final product. [Figure 10] FIG. 10 is a partial cross-sectional view of the edge of an exemplary vacuum glazing assembly including an interior space and a metal bridge element that isolates the interior space from the ambient environment. [Figure 11] FIG. 11 is a partial cross-sectional view showing a cross section of a rotating sonotrode for forming cold welds between each edge of the metal bridge element of FIG. 1 and its respective substrate. [Figure 12] FIG. 12 is a partial cross-sectional view showing a cross section of a rotating sonotrode for forming a cold weld between each edge of the metal bridge element of FIG. 1 and its respective substrate, such that the cold weld includes at least two high-tight seal elements. [Figure 13] FIG. 13 is a partial cross-sectional view showing an alternative cross section of a rotating sonotrode for forming a cold weld between each edge of the metal bridge element of FIG. 1 and its respective substrate, such that the cold weld includes at least two high-tight seal elements. DETAILED DESCRIPTION OF THE INVENTION

[0031] Before any embodiments of the invention are described in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the above drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways without departing significantly from the spirit thereof.

[0032] definition Approximate terms such as "about," "generally," "approximately," or "substantially" include values ​​10 percent greater or less than the stated value. When used in the context of angles or directions, such terms include angles or directions within 10 degrees greater or less than the stated angle or direction. For example, "approximately perpendicular" includes directions within 10 degrees of perpendicular in any direction (e.g., clockwise or counterclockwise).

[0033] As used herein, the terms "isolation glazing unit" and "glass panel assembly" are synonymous and refer to a glazing assembly formed from one or more glass members or elements (referred to as glass panes for purposes of discussion) that are at least partially transparent to electromagnetic radiation, are substantially parallel along their planes, and are of substantially congruent shape with peripheral edges sealed to form an interior space between the panes. These terms also encompass flat panel assemblies having at least one element comprising glass and another element that may comprise glass, ceramic, aluminum, stainless steel, or other materials. The interior space may be at least partially filled or evacuated (e.g., by applying a vacuum) with a gas that is less conductive than air and, in some configurations, more viscous than air.

[0034] The term "glass pane" refers to a glass element intended for use as a wall element or substrate in a flat, hermetically sealed container assembly.

[0035] "Differential pane movement" refers to the relative pane movement between two adjacent panes that occurs when the temperature of one pane changes relative to the temperature of the other pane. It may also refer to the relative pane movement that occurs under mechanical or other influences (e.g., impact during handling or use).

[0036] "Hermeticity" or "level of hermeticity" refers to a measure of the maximum leak rate a seal is capable of, for example, standard cubic centimeters of helium per second per centimeter of seal length ("sccs / cm") or an equivalent measurement. Generally, a higher hermeticity corresponds to a lower leak rate, and vice versa.

[0037] "Hermetic" refers to a seal that is capable of achieving a hermeticity appropriate or specified for the application. It is recognized that different areas within a cold weld may have different levels of hermeticity, and that an area within a cold weld may be described as hermetic without inferring that the hermeticity of that area is the same as other areas within the same cold weld.

[0038] The term "highly-malleable" refers to an object or material having a yield stress of 10,000 psi or less (e.g., 5,500 psi or less).

[0039] The term "solid-state" in reference to welding or coating refers to a joining process that does not involve melting of the materials being joined.

[0040] The term "cold-weld" refers to a solid-state process for joining two or more parts.

[0041] The term "sonotrode" refers to an oscillating tool that transmits translational motion to an assembly of substrates being welded by an ultrasonic bonding device.

[0042] The term "inboard" refers to the location of a first feature relative to a second feature on an assembly having a generally planar shape, the location of the first feature on the side of the second feature that is closer to the center of gravity of the generally planar shape.

[0043] The term "outboard" refers to the location of a first feature relative to a second feature on an assembly having a generally planar shape, the location of the first feature on the side of the second feature that is farther from the center of gravity of the generally planar shape.

[0044] The term "bridge element" means an element that is bonded to one or more substrates to isolate the resulting interior space from the environment.

[0045] The term "nip" refers to the area of ​​the sonotrode trim that contacts the metal foil of the bridge element 4.

[0046] The term "faying surfaces" refers to the friction surfaces of the foil area in the nip against the corresponding area of ​​the substrate, where friction under pressure causes rapid heating to produce a bond at the interface between the faying surfaces.

[0047] The term "channeled" refers to a sonotrode shape with parallel circumferential channels formed in the rim.

[0048] Detailed Description 1 and 2 illustrate an exemplary product (e.g., a MEMS package) embodying the present invention and including a wall element or substrate defining an interior space (also referred to as an evacuable gap or interior region) that is sealed and isolated from the environment surrounding the substrate. The substrate is non-metallic (e.g., glass, such as a glass sheet) and includes a base and an edge that cooperate to define the interior space. A sealing element is attached to the substrate to enclose the interior space and seal it from the ambient environment. A schematic diagram of an exemplary sealing element is shown in FIG. 7B. As shown, the sealing element is defined by a metal or metal layer (referred to as a metal layer for purposes of the specification and claims) and a metal bridge element or foil (e.g., aluminum). The metal layer defines a coating deposited or otherwise disposed on the edge (e.g., around the periphery of the substrate consistent with FIG. 2). The bridge element is attached to the metal layer (e.g., by a solid-state welding process) and extends over the interior space, providing a hermetic seal for the interior space. The bridge element may be formed from one or more layers of metal foil.

[0049] 3A and 3B illustrate another exemplary product (e.g., a window assembly) embodying the present invention. The product includes a first substrate (e.g., a glass plate or sheet) and a second substrate (e.g., a glass plate or sheet) spaced apart from the first substrate to define an interior space (i.e., an evacuable gap). The first and second substrates can be spaced apart in different ways, including by a spacer formed from an incompressible or substantially incompressible material (e.g., composite, plastic, glass, metal, etc.). Sealing elements are attached to the substrates to enclose the interior space and seal it from the ambient environment. As shown, the sealing elements are attached to each side of the substrates (i.e., surfaces facing each other). In some configurations, the sealing elements can be attached to the sides facing away from each other, to each edge of the substrates, or a combination thereof.

[0050] Continuing with reference to FIGS. 3A and 3B, the sealing element is defined by a metal layer deposited or disposed on each of the first and second substrates and a metal bridge element or foil (e.g., aluminum) attached to and extending between the metal layers. The metal layer on each substrate is deposited or applied to the substrate to define the boundary of the interior space to be evacuated. In the illustrated example, the metal layer is applied continuously around the periphery of the interior space. Bridge elements are attached (e.g., by a solid-state welding process) to the metal layer across the lateral portions of the interior space (i.e., between the substrates), hermetically sealing the interior space. The solid-state welds define a joint between the bridge element and the metal layer and cooperate with the sealing element to seal the interior space. In some configurations, a getter material can be disposed in the space or gap between portions of the bridge element.

[0051] A second weld (e.g., laser welding, MicroTIG welding, resistance welding, cold metal transfer, solder reflow, ultrasonic soldering, or other rapid welding) can be applied to the outer extent of the bridge element and each substrate to further provide a hermetic seal for the interior space. The second weld defines the bond of the bridge element to each of the first and second substrates. That is, a portion of the bridge element is joined to the first substrate by the second weld, and another portion of the bridge element is joined to the second substrate by the second weld. In some configurations, the second weld can be performed in a vacuum chamber to eliminate the need for an exhaust port extending through one of the substrates.

[0052] 1-3B show two exemplary products that include sealing elements, it will be understood that other products can include sealing elements (eg, flat panel displays, instrumentation, etc.).

[0053] 4 illustrates an exemplary process having three main steps for manufacturing a sealing element (either hermetic or non-hermetic) and for positioning and attaching the sealing element to a substrate. It will be understood that FIG. 4 encompasses a general process, and additional steps can be incorporated into the process to facilitate the formation of the sealing element and the positioning and attachment of the sealing element onto a substrate. The general process includes i) metallizing a non-metallic substrate, ii) bonding a metallic bridge element to the metallized substrate, and iii) incorporating the assembly into a product.

[0054] In the first major step (step 100), a metal layer (e.g., aluminum) is applied to a non-metallic substrate using a process or method that does not include an oven for heating the substrate and does not use a vacuum chamber (i.e., an oven-free, vacuum-chamber-free process). Figures 5A and 5B illustrate an exemplary method using frictional surface treatment to metallize a non-metallic substrate. Using frictional surface treatment, and referring to Figures 7A and 7B, a malleable metal (e.g., aluminum) is applied to the non-metallic substrate. Frictional surface treatment involves pressing a metal consumable (e.g., a "mechatrode" formed from a malleable metal) onto the surface of the non-metallic substrate and moving (i.e., moving relative to) one or both of the metal consumable and the substrate to deposit or transfer the malleable metal onto the surface. This step, shown in Figure 7A, forms a metal layer on the non-metallic substrate. As shown in Figure 5A, the metal consumable is generally flat (i.e., not angled) relative to the substrate during the transfer of the metal onto the substrate. As shown in Figure 5B, the metal consumable is angled relative to the substrate during transfer of the metal onto the substrate. In some configurations, a stable gas (e.g., argon) can be used to exclude oxygen during the friction surface treatment process. The metal layer is attached to the substrate and defines an adhesion layer to which the metal bridge element can be attached. As shown in Figure 2, the metal layer extends continuously along or around the perimeter of the interior space.

[0055] In the second major step (step 105), referring to FIG. 7B, a metal bridge element is attached to the metal layer. FIG. 6 illustrates one exemplary process that involves cold welding the metal bridge element to the metal layer. The sonotrode of an ultrasonic seam welder can be used to weld the metal bridge element to the metal layer. Ultrasonic welding and other cold welding processes are well known and therefore will not be described in detail.

[0056] Referring back to Figure 4, the third major step (step 110) involves further processing of the substrate seal element assembly to produce a product such as a vacuum insulated glass assembly (e.g., a window assembly or flat panel display) in which the interior space is exposed to a vacuum. Further processing of the assembly can take many forms, including igniting the getter within the interior space and, in some cases, a secondary welding or sealing step necessary to ensure that the interior space can be evacuated. It will be understood that a second step may be included within or after each of the above major steps, and that additional major steps may be used to complete the VIG.

[0057] While Figures 5A-7A and 8 are described above in connection with forming a sealing element, it will be understood that these figures also illustrate how frictional surfacing can be used to apply, form, or apply a metal layer to a non-metallic substrate, with or without forming a sealing element. For example, the process of applying a metal layer to a non-metallic substrate as described and illustrated herein can be applied in a three-dimensional ("3D") printing process to form a metal layer or coating on a substrate having a metal oxide layer (e.g., bonding aluminum to a substrate having an aluminum oxide layer). The process can also be used to fabricate one or more metal layers or traces on substrates used in vehicle windows (e.g., for defrosting purposes; see Figure 9) or to manufacture solar panels where the seal between portions of the solar panel does not need to be hermetic. The process of applying a metal layer or coating to a non-metallic substrate described herein can also be used in other applications.

[0058] Example Example 1: Two square panes of 10" x 10" untempered window glass are cut and cleaned by conventional means. A metal layer forming a coating of 1100 series aluminum is applied to each pane in the form of an approximately 3 mm wide ribbon on all four sides adjacent to its edges using a friction surface treatment. Process parameters are selected to minimize the inclusion of aluminum oxide between the unoxidized aluminum and the glass, and to eliminate tearing or other damage to the glass surface so that the interface between the metal coating and the glass is highly sealed and continuous along the perimeter of the area that will later be evacuated. Each pane is then completely covered with a 75 micron thick layer of 1100 series aluminum foil, and the edges are ultrasonically welded to the metal layer. The area of ​​each foil piece inside the weld path is trimmed to form a visible window-like area. The foiled panes are then placed together so that their edges are aligned with the foil bridge elements contacting each other. The edges of the foil bridge elements are cut flush with the edges of the glass pane assembly, and the foil elements are welded together using a laser to form a sealed bridge element that connects the ribbons of metallic adhesive coating on their respective panes. The welded assembly is then evacuated through a small port through one pane of glass. The port is then sealed. The assembly can then be used as a 10-inch by 10-inch square vacuum insulated glass unit.

[0059] It is to be understood that the present invention may be embodied in other specific forms or incorporate combinations of the embodiments described herein without departing from the spirit or characteristics of the invention. While specific embodiments have been illustrated and described, other modifications may be made without significantly departing from the spirit of the invention.

[0060] Example 2: A MEMS device can be designed to communicate data using light. To enable optical communication, the device is hermetically sealed within a small rectangular glass container (e.g., 25 mm x 15 mm x 5 mm with an open cavity with 3 mm thick walls, similar to the configuration shown in Figure 1). The container is cleaned by conventional means. A coating of 6061 series aluminum is applied to the top of the wall adjacent to the cavity opening in the form of a continuous ribbon (e.g., approximately 3 mm wide and 1 micron thick) using a friction surface treatment. Lasers and infrared thermometers in a closed-loop control system are used to maintain a consumable mechatrode (e.g., formed 6061 aluminum, the same material as the coating) at 200°C to slightly reduce the yield strength of the 6061 aluminum forming the mechatrode. This reduces the risk of tearing the glass surface at the top of the wall.

[0061] The mechatrode is tilted 45 degrees from vertical in a vertical plane containing the ribbon centerline, with automation suitable for maintaining both the linear and rotational speeds of the mechatrode constant or substantially constant and rotating the tilted mandrel to guide the ribbon around the corner. The linear speed of the contact point between the mechatrode and the glass is maintained at 150 mm / min. The mechatrode rotational speed setting is selected to result in a relative velocity of approximately 100,000 mm / s between the mechatrode surface and the contact point with the glass. The vertical force on the mandrel is maintained at approximately 1 kgf. The path of the automated motion is closed so that the end of the ribbon overlaps with its beginning, forming a continuous coating around the cavity perimeter. The container is then passed through a vacuum oven, which serves as a load lock, into a helium-filled glove box maintained in dry conditions with a dew point below -60°C. Using gloves made of a suitable flexible and impermeable material, the operator inserts the MEMS device into the cavity of the metallized glass container, and the cavity opening is covered with a small coupon of 150 microns thick 1100-12H aluminum foil. Using a properly designed electrode, contact with the coating layer on the glass is maintained to enable resistance welding, resulting in a hermetic seal between the aluminum foil and the conductive aluminum coating on the glass, trapping dry helium within the cavity and excluding air and moisture from the environment.

[0062] Example 3: Two sheets of tempered window glass (e.g., approximately 2 m x 3 m in size) are cut and cleaned by conventional means. One of the sheets has a low-emissivity coating and is edge-cleaned (i.e., the portion of the low-emissivity coating along the path to be sealed is removed) using a method that does not mechanically damage the surface of the glass sheet. A metal layer forming a coating of 1100 series aluminum is applied to the sides adjacent to all four edges of each sheet of glass in the form of a ribbon (e.g., approximately 2 mm wide and 1 micron thick) using a friction surface treatment. During the coating process, a flow of industrial-grade argon is used to blanket the area of ​​the environment surrounding the contact point between the mechatrode and the glass sheets to prevent further formation of aluminum oxide on the joining surface. To avoid cooling the joining surface, the argon is slightly heated to 50 °C.

[0063] The mechatrode is tilted 30 degrees from vertical in a vertical plane containing the ribbon centerline, with automation suitable for maintaining both the linear and rotational speeds of the mechatrode constant and for rotating the tilted mandrel to guide the ribbon around the corner. The linear speed at the point of contact between the mechatrode and the glass plate is maintained at 300 mm / min. The mechatrode rotational speed setting is selected to result in a relative velocity of approximately 200,000 mm / sec at the point of contact of the mechatrode surface with the glass. The normal force on the mandrel is maintained at approximately 0.5 kgf. The path of the automated motion is closed so that the end of the ribbon overlaps the beginning of the ribbon, forming a highly sealed coating between the metal and glass and an uninterrupted bond around the cavity perimeter.

[0064] Each glass pane is completely coated with a layer of 1100 series aluminum foil (e.g., 75 microns thick), and the edges of the foil are laser welded to the metal layer using an argon blanket, resulting in a highly sealed, continuous bond between the foil and the metal coating on the glass along the perimeter of the evacuated area. The area of ​​each foil piece inside the weld path is trimmed to form a visible area (e.g., a window) that forms a foil bridge element. The foil-covered glass panes are then placed together so that their edges align with the foil bridge elements, which are in contact with each other. The edges of the foil bridge element are cut flush with the edges of the glass pane assembly. All but a 300 mm long section of the foil element's periphery is then welded using a tungsten inert gas (TIG) process using an argon blanket to form a highly sealed bridge element that connects to the metal ribbon (also known as the adhesive coating) on ​​each glass pane. Using a suitable exhaust fixture with a transparent window to create a seal around the 300mm long unwelded section, the partially welded assembly is vented through the gap between the two foil layers along the unwelded section. A laser passing through the window in the exhaust fixture is used to weld the unwelded section, completing a highly hermetic perimeter weld. The rectangular assembly can then be used as a vacuum insulated glass unit.

[0065] Example 4: A strip of glass measuring 50 mm x 1000 mm x 3 mm thick is cut and cleaned by conventional means. A coating of 1100 series aluminum is applied to the side using a friction surface treatment in the form of a metal ribbon approximately 2 microns thick, 3 mm wide, and 990 mm long. During the coating process, a flow of argon (e.g., industrial-grade argon) is used to blanket the area surrounding the contact point between the mechatrode and the glass to prevent the formation of aluminum oxide on the interface. The argon is cooled slightly to 10°C to remove heat generated at the interface. The mechatrode is tilted 70 degrees from vertical in a vertical plane (orthogonal to the ribbon centerline) with automation suitable for maintaining both the linear and rotational speeds of the mechatrode constant. The linear speed at the contact point between the mechatrode and the glass is maintained at 100 mm per minute. The rotational speed setting of the mechatrode is selected to result in a relative speed of approximately 100,000 mm per second at the point of contact of the mechatrode surface with the glass. The normal force on the mandrel is maintained at approximately 1 kgf. The path of the automated motion is linear in this example. Next, a ribbon of 1100 series aluminum foil (e.g., 125 microns thick and 6 mm wide) is ultrasonically seam welded to the metal coating pre-applied to the glass strip, with the longitudinal centerline of the aluminum foil ribbon approximately aligned with the longitudinal centerline of the metal ribbon. The bond between the foil and the resulting metal coating is mechanically strong, and the bond characteristics can be hermetic or non-hermetic. The glass strip in this example can be incorporated into a solar panel collector, with the aluminum foil ribbon acting as a common busbar for collecting current from the individual solar cells on the glass plate.

[0066] Some examples are described and illustrated with respect to forming or applying a metal layer or coating on a substrate formed from or including glass (e.g., to facilitate the formation of a seal element, or to facilitate a connection between a metal bridge element and a glass substrate, whether in connection with the formation of a seal element, or unrelated thereto). It will be understood that the invention described herein is equally applicable to forming a metal layer or coating on other non-metallic substrates and is not limited to glass substrates.

[0067] FIG. 10 illustrates a portion of an exemplary vacuum glazing assembly 1 (e.g., a window assembly configured for installation on the exterior wall of a building) including a first substrate 2 (e.g., a first glass pane) and a second substrate 3 (e.g., a second glass pane) spaced apart from the first substrate 2 to define an interior space 10 (also referred to as an evacuable gap or interior region) that is sealed and isolated from the environment surrounding the vacuum glazing assembly 1. One or more glass pane spacers 9 formed from an incompressible or substantially incompressible material (e.g., composite, plastic, glass, metal, etc.) may be disposed in the interior space 10 between the substrates 2 and 3 to maintain a consistent gap width between the substrates 2 and 3. In the illustrated embodiment, the substrates 2 and 3 are non-metallic (e.g., glass, such as annealed glass or tempered glass). In other embodiments, one or both of the substrates 2 and 3 may be metallic. A metallic bridge element 4 is attached to each of the substrates 2 and 3 and seals the interior space 10 from the ambient environment.

[0068] 10 , the metal bridge element 4 can be formed from one or more layers of metal foil (e.g., aluminum foil). For convenience and cost savings, the bridge element 4 can be formed from two pieces, each cold-welded to its respective substrate and later combined into a single bridge element 4 by forming a hermetic foil-to-foil connection weld 5 (e.g., a fusion weld such as laser welding, MicroTIG welding, resistance welding, or the weld 5 can include a solid-state weld). In other embodiments, the bridge element 30 can be integrally formed from a single piece of material.

[0069] Referring to FIG. 10 , bridge element 4 is attached to each of substrates 2, 3 by cold welds 6. Each cold weld 6 has a first sealing element 7 (e.g., weld) and a second sealing element 8 (e.g., weld) extending parallel to first sealing element 7. Bridge element 4 extends across interior space 10 along its peripheral boundary (i.e., between substrate 2 and substrate 3) to hermetically seal interior space 10. Cold welds 6 provide a structural connection between bridge element 4 and substrates 2, 3. That is, cold welds 6 are configured to withstand forces and stresses due to thermal expansion or differential glass sheet movement. In some embodiments, the structural connection between bridge element 4 and substrates 2, 3 defined by cold welds 6 has a shear strength greater than the tensile strength of bridge element 4 itself.

[0070] Figure 11 shows a rotating sonotrode 21 including a rim 22 with a smooth circumferential contour (e.g., a cylindrical contour). The sonotrode 21 can be used to make multiple successive passes over the bridge element 4 to form the sealing elements 7, 8 (e.g., continuous parallel welds or sealing elements) shown in Figure 10. Some embodiments of the sonotrode incorporate a textured rim (e.g., checkerboard or roughness) to reduce slippage in the nip between the sonotrode and the metal foil and promote maximum slippage between the faying surfaces.

[0071] FIG. 12 illustrates another rotary sonotrode 21 including a rim 22 having channels 23 configured to form the sealing elements 7, 8 (e.g., simultaneous parallel welds or sealing elements) shown in FIG. 10 in a single pass of the rotary sonotrode 21. As shown, the sonotrode 21 has two channels 23 that extend circumferentially around the rim 22 and are parallel to one another. The channels 23 may be formed by machining the rim 22 or by other suitable processes (e.g., molding, etc.). The sonotrode 21 does not include a checkerboard texture; that is, no channels extend perpendicular or at an acute angle to the parallel circumferential channels. The profile of FIG. 12 facilitates the formation of parallel sealing elements 7, 8 in parallel through the channels 23.

[0072] FIG. 13 illustrates another rotary sonotrode 21 including a rim 22 having at least three ribs 24 and channels 23 disposed between the ribs 24. The ribs 24 are parallel to one another and extend circumferentially around the sonotrode 21, and the channels 23 similarly extend circumferentially around the rim 22 and are parallel to one another. The rotary sonotrode 21 of FIG. 13 is configured to form the sealing elements 7, 8 (e.g., parallel welds or sealing elements) shown in FIG. 10 in a single pass of the rotary sonotrode 21. The ribs 24 may be machined into the rim 22 or formed by other suitable processes (e.g., molding, etc.). The sonotrode 21 does not include a checkerboard texture. That is, there are no channels extending perpendicular or at an acute angle to the parallel circumferential channels. The profile of FIG. 13 facilitates forming the parallel sealing elements 7, 8 side by side through the channels 23.

[0073] The metal bridge element can provide a hermetic seal between two substrates of a vacuum glass assembly. The hermetic seal can be formed by bonding the metal bridge element to each of the two substrates to form at least two hermetic sealing stages. A sealing material can be applied in at least partial contact with a first of the two hermetic sealing stages, and the sealing material can be cured (e.g., heated) to form a second hermetic sealing stage. Bonding the metal bridge element to each of the two substrates can be achieved by cold welding. In one example, the metal bridge element is formed of a material including at least one material selected from the group consisting of aluminum, titanium, and copper.

[0074] It will be understood that more than one seal element may be formed by an exemplary sonotrode, and the formation of the seal elements may be sequential, simultaneous, or a combination thereof. For example, by increasing the amount of circumferential channels 23 in the profile of the rotating sonotrode rim 22, three or more seal elements 7, 8 may be formed in the foil-to-substrate cold weld 6. For example, a sonotrode 21 having a rim 22 with three channels 23 (e.g., formed by four adjacent ribs 24 or defined in the surface of the sonotrode rim 22) may be used to form three simultaneous parallel seal elements 7, 8 through the channels 23 (i.e., a three-part seal element or triple simultaneously formed seal elements).

[0075] Forming at least two spaced apart seal elements 7, 8 in accordance with the embodiments and sonotrode features described and illustrated herein offers numerous advantages over the use of a single seal element. For example, the second seal element 8 provides a redundant hermetic seal for the first seal element 7 that can maintain the integrity of the cold weld 6 if the hermeticity of the first seal element 7 is compromised by any of a variety of different mechanisms, including a non-piercing defect (e.g., a scratch, wrinkle, etc.) in the metal bridge element 4 or a defect (e.g., a scratch, etc.) in the substrates 2, 3. In some embodiments, two spaced apart seal elements 7, 8 may also provide a longer service life for the VIG. However, if a single flaw (e.g., a glass scratch) extends across both seal elements 7, 8, a path for inflow of gas molecules may exist, reducing VIG life.

[0076] A significant advantage of the foil-to-substrate cold weld 6 according to the embodiments described and illustrated herein is that the metallic bridge element 4 is in strong mechanically bonded contact with the non-metallic substrate. Portions of the cold weld 6 are highly hermetic (i.e., seal elements 7, 8), while the remainder of element 6 is less hermetic, yet provides significant additional mechanical strength, thereby partially mechanically isolating the highly hermetic seal elements 7, 8 from stresses arising from sources external to element 6 (e.g., differential glass sheet movement, thermal gradients).

[0077] Because the seal elements 7, 8 are spaced apart, residual gas molecules can be trapped in tiny pockets in the inter-seal space 11. Nevertheless, the number of molecules is relatively small (because the trapped volume is negligible), and the less tight sections of the cold weld 6 provide a highly tortuous path for molecules that can migrate from the inter-seal space 11 into the gap 10. Our research has shown that VIG performance can withstand full-length cyclic temperature tests similar to or even more rapid than those described in the accelerated life test standard "ASTM E2188-19 Standard Test Method for Insulating Glass Performance."

[0078] In embodiments of the present invention, the foil-to-substrate cold welds 6 are formed by a rotary seam ultrasonic welder. In some embodiments, a bar-type ultrasonic welder can be used.

[0079] 1 shows an exemplary product incorporating the present invention, it will be understood that other products (e.g., flat panel displays, neutron detectors, solar panels) may be beneficial. Thus, the present invention described and claimed herein should not be construed to encompass only window assemblies.

[0080] It is to be understood that the present invention may be embodied in other specific forms or incorporate combinations of the embodiments described herein without departing from the spirit or characteristics of the invention. While specific embodiments have been illustrated and described, other modifications may be made without significantly departing from the spirit of the invention.

[0081] Although the present invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described. It will be understood that each feature of the invention may form the basis of one or more claims, either by itself or in any combination with any other feature. The order in which the invention has been described is not intended to inform the reader of the features alone or in combination, even if the features may be novel and inventive. That is, the order in which the invention has been described is merely for convenience and should not be construed as limiting with respect to what may be claimed.

[0082] Various aspects and preferred embodiments of the present invention are presented with reference to the following sections.

[0083] Item 1. A vacuum glazing assembly having first and second spaced apart substrates connected to one another by a sealing element to form a vacuum interior space therebetween. The sealing element may be formed by joining a metal bridge element to at least one of the substrates by a cold weld.

[0084] Item 2. In some embodiments, the cold weld comprises at least two spaced apart, tight-tight seal elements that are created simultaneously during bonding to at least one of the substrates.

[0085] Item 3. In some embodiments, each sealing element is formed by ultrasonic welding.

[0086] Item 4. In some embodiments, the formation of each of the two seal elements is accomplished by rotary ultrasonic welding.

[0087] Item 5. In some embodiments, the cold weld comprises contacting a metal bridge element with a vibrating sonotrode.

[0088] Item 6. In some embodiments, the formation of the sealing element is achieved by using a rotating sonotrode having parallel ribs on the rim of the rotating sonotrode.

[0089] Item 7. In some embodiments, the glass is coated with a thin metal layer prior to bonding of the metal bridge element.

[0090] Item 8. In some embodiments, the seal elements are formed by joining metal bridge elements to each of the substrates, with respective cold welds forming parallel seal elements on each of the substrates.

[0091] Item 9. In some embodiments, an evacuated glass assembly includes a first substrate, a second substrate spaced apart from the first substrate to define an interior space therebetween, and a metal bridge element disposed between the first and second substrates and hermetically isolating the interior space from an ambient environment.

[0092] Clause 10. In some embodiments, the bridge element includes a first seal element formed by a cold weld bond between the metallic bridge element and the first substrate, and a second seal element spaced from the first seal element and formed by a cold weld bond between the metallic bridge element and the first substrate.

[0093] Item 11. In some embodiments, the first and second seal elements are formed simultaneously.

[0094] Clause 12. In some embodiments, each of the first seal element and the second seal element defines a structural connection between the metallic bridge element and the first substrate that has a shear strength greater than the yield strength of the metallic bridge element.

[0095] Clause 13: In some embodiments, both the first seal element and the second seal element partially define the seal of the vacuum assembly.

[0096] Item 14. A method for forming a metallic bridge element for hermetically sealing between two substrates of a vacuum glass assembly, the method including the steps of bonding a metallic bridge element to each of the two substrates to form at least two hermetically sealed stages, applying a sealing material in at least partial contact with a first of the hermetically sealed stages, and curing the sealing material to form a second of the hermetically sealed stages.

[0097] Item 15. In some embodiments, joining the metallic bridge element to each of the two substrates is accomplished by cold welding.

[0098] Item 16. In some embodiments, the metallic bridge element material comprises at least one selected from the group consisting of aluminum, titanium, and copper.

[0099] Clause 17. A structural element for a building, comprising at least two spaced apart non-metallic substrates connected to one another by a sealing element to form an evacuable gap therebetween, the sealing element being formed by subjecting at least one surface of each of the non-metallic substrates to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on each of the substrates.

[0100] Clause 18. The metallic layer on each of the non-metallic substrates may define a continuous coating along the periphery of the evacuable gap.

[0101] Item 19. In some embodiments, the sealing element is further formed by connecting a metal bridge element to the metal layer to form a seal of the evacuable gap.

[0102] Item 20. In some embodiments, the metal deposition process includes a friction surface treatment.

[0103] Item 21. In some embodiments, the bridge element is connected to the metal layer by ultrasonic welding.

[0104] Item 22. In some embodiments, the substrate comprises glass.

[0105] Clause 23: In some embodiments, the bridge element comprises a metal foil and the seal is hermetic.

[0106] Item 24. A method of manufacturing a structural element including first and second substrates of substantially coincident shape, the method including forming a seal element between the substrates to define an evacuable gap.

[0107] Clause 25. The sealing element may be formed by a process of subjecting at least one surface of each substrate to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on the substrate, the metal layer defining a continuous coating along the periphery of the evacuable gap.

[0108] Item 26. In some embodiments, the sealing element is further formed by connecting a bridge element to the metal layer to define a hermetic seal of the evacuable gap.

[0109] Item 27. In some embodiments, the metal deposition process includes a friction surface treatment.

[0110] Clause 28: In some embodiments, the bridge element is connected to the metal layer by ultrasonic welding.

[0111] Clause 29: In some embodiments, the bridge element comprises a metal foil.

[0112] Item 30. In some embodiments, the substrate comprises glass.

[0113] Item 31: An insulated glass unit including a first flat panel element and a second flat panel element, the first and second flat panel elements having precisely matching congruent shapes. The glass unit also includes a plurality of spacers disposed between the first flat panel element and the second flat panel element to space the first flat panel element from the second flat panel element, and a sealing element connecting the first flat panel element and the second flat panel element to form an evacuable gap therebetween.

[0114] Clause 32. In some embodiments, the sealing element is formed by a process of subjecting at least one surface of each substrate to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on each substrate, wherein the metal layer defines a continuous coating along the periphery of the evacuable gap, and connecting a bridge element to the metal layer to form a hermetic seal of the evacuable gap.

[0115] Clause 33: A method of manufacturing a structural element including a substrate defining an interior space, the method including forming a seal element to enclose the interior space and define an evacuable gap.

[0116] Clause 34. In some embodiments, the sealing element may be formed by a process in which a surface of a substrate is subjected to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on the substrate, the metal layer defining a continuous coating along the periphery of the interior space, and a bridge element connecting the metal layer and extending across the interior space to define a seal of the evacuable gap.

[0117] Clause 35. In some embodiments, the connecting step includes defining a hermetic seal.

[0118] Clause 36: A process for making a sealing element for incorporation into an envelope having an interior region isolated from the environment, the process including subjecting a surface of a wall element to an oven-free and vacuum chamber-free metal deposition process to form a metal layer that extends continuously along the periphery of the interior region so as to isolate it from the environment, and connecting a bridge element to the metal layer to form the sealing element along the periphery of the interior region.

[0119] Clause 37. In some embodiments, the connecting step includes defining a hermetic seal.

[0120] Item 38. A method for manufacturing a structural element, the method including the steps of: subjecting a surface of a non-metallic substrate to an oven-free, vacuum chamber-free metal deposition process including a friction surface treatment to form a metal layer on the substrate, the metal layer defining a coating on the substrate; and connecting a metal foil to the metal layer.

[0121] Clause 39. A structural element comprising a non-metallic substrate comprising a metal layer on at least a portion of the substrate formed using a friction surface treatment process, and a metal foil attached to the substrate via the metal layer.

[0122] Item 40. In some embodiments, the frictional surface treatment process comprises subjecting at least one surface of the substrate to an oven-free, vacuum chamber-free metal deposition process.

[0123] Item 41. A method for manufacturing a structural element. The method includes subjecting a surface of a non-metallic substrate to an oven-free, vacuum chamber-free metal deposition process that includes a frictional surface treatment to form a metal layer on at least a portion of the substrate.

[0124] Item 42. In some embodiments, the metal layer defines a coating on the substrate.

[0125] Item 43. In some embodiments, the non-metallic substrate comprises a vehicle window, and the metal layer is formed in a line extending along the length or width of the vehicle window.

[0126] Although the invention has been described with reference to certain embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described.

[0127] Various features of the invention are set forth in the following claims.

Claims

1. 1. A vacuum glass assembly having a first substrate and a second substrate spaced apart and connected to one another by a sealing element, forming a vacuum interior space therebetween, 1. A vacuum glazing assembly comprising: a metal bridge element joined to at least one of the substrates by cold welding, the metal bridge element comprising at least two spaced apart, high-tight seal elements that are simultaneously created during joining to at least one of the substrates.

2. 10. A vacuum glazing assembly according to claim 1, wherein each sealing element is formed by ultrasonic welding.

3. 3. The vacuum glazing assembly of claim 2, wherein forming each of the two sealing elements is accomplished by rotary ultrasonic welding.

4. 10. The vacuum glazing assembly of claim 1, wherein said cold welding comprises contacting said metal bridge element with a vibrating sonotrode.

5. 5. The vacuum glazing assembly of claim 4, wherein forming the sealing element is accomplished by using a rotating sonotrode having parallel ribs on its rim.

6. 10. The vacuum glazing assembly of claim 1, wherein the glass is coated with a thin metal layer prior to bonding of the metal bridge element.

7. 10. The vacuum glazing assembly of claim 1, wherein the sealing elements are formed by joining metal bridge elements to each of the substrates, each cold weld forming a parallel sealing element on each of the substrates.

8. a first substrate; a second substrate spaced apart from the first substrate and defining an interior space between the second substrate and the first substrate; a metal bridge element disposed between the first substrate and the second substrate, hermetically isolating the interior space from an ambient environment, a first sealing element formed by a cold weld joint between the metal bridge element and the first substrate; a second sealing element spaced from the first sealing element and formed by a cold weld joint between the metal bridge element and the first substrate; a metal bridge element including: Including, The first sealing element and the second sealing element are formed simultaneously.

9. 9. The vacuum glazing assembly of claim 8, wherein each of the first seal element and the second seal element defines a structural connection between the metal bridge element and the first substrate having a shear strength greater than a yield strength of the metal bridge element.

10. 10. The evacuated glazing assembly of claim 9, wherein both the first sealing element and the second sealing element partially define a hermeticity of the evacuated glazing assembly.

11. 1. A method of forming a metallic bridge element for a hermetic seal between two substrates of a vacuum glazing assembly, comprising: bonding a metal bridge element to each of the two substrates to form at least two hermetically sealed stages; applying a sealing material in at least partial contact with a first one of the sealing stages; and curing the sealing material to form a second one of the hermetic seal stages.

12. The method of claim 10 , wherein joining the metallic bridge element to each of the two substrates is accomplished by cold welding.

13. The method of claim 11 , wherein the metallic bridge element material comprises at least one selected from the group consisting of aluminum, titanium, and copper.

14. 1. A structural element for a building having at least two spaced apart non-metallic substrates connected to one another by a sealing element forming an evacuable gap therebetween, said sealing element comprising: subjecting at least one surface of each of the non-metallic substrates to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on each of the substrates, the metal layer on each of the non-metallic substrates defining a continuous coating along a periphery of the evacuable gap; a metal bridge element connecting the metal layer to form a seal of the evacuable gap; A structural element formed by:

15. The structural element of claim 14 , wherein the metal deposition process comprises a friction surface treatment.

16. 15. The structural element of claim 14, wherein the bridge element is connected to the metal layer by ultrasonic welding.

17. The structural element of claim 14 , wherein the substrate comprises glass.

18. The structural element of claim 14 , wherein the bridge element comprises a metal foil and the seal is hermetic.

19. 1. A method of manufacturing a structural element comprising first and second substrates of substantially coincident shape, comprising: forming a sealing element between the substrates to define an evacuable gap; The sealing element subjecting at least one surface of each substrate to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on the substrate, the metal layer defining a continuous coating along the perimeter of the evacuable gap; A bridge element is connected to the metal layer to define a hermetic seal of the evacuable gap. The method of claim 1, wherein the compound is formed by:

20. The method of claim 19 , wherein the metal deposition process comprises a friction surface treatment.

21. 20. The method of claim 19, wherein the bridge element is connected to the metal layer by ultrasonic welding.

22. The method of claim 19 , wherein the bridge element comprises a metal foil.

23. The method of claim 19 , wherein the substrate comprises glass.

24. a first flat panel element; a second flat panel element having the same shape as the first flat panel element; a plurality of spacers disposed between the first flat panel element and the second flat panel element, the spacers spacing the first flat panel element from the second flat panel element; a sealing element connecting the first flat panel element and the second flat panel element to form an evacuable gap therebetween; and The sealing element subjecting at least one surface of each substrate to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on each of said substrates, said metal layer defining a continuous coating along a periphery of said evacuable gap; by connecting a bridge element to the metal layer to form a hermetic seal of the ventable gap. An insulating glass unit characterized by:

25. 1. A method of manufacturing a structural element including a substrate defining an interior space, comprising: forming a sealing element to surround the interior space and define an evacuable gap; The sealing element subjecting a surface of the substrate to an oven-free, vacuum chamber-free metal deposition process to form a metal layer on the substrate, the metal layer defining a continuous coating along a periphery of the interior space; connecting a bridge element to the metal layer, the bridge element extending across the interior space to define an evacuable gap seal.

26. 26. The method of claim 25, wherein the connecting step includes defining a hermetic seal.

27. 1. A method for making a sealing element for incorporation into an envelope having an interior region isolated from the environment, comprising: subjecting a surface of the wall element to an oven-free and vacuum chamber-free metal deposition process to form a metal layer extending continuously along the periphery of the interior region isolated from the environment; connecting a bridge element to the metal layer to form a seal element along the perimeter of the interior region; A method comprising:

28. 28. The method of claim 27, wherein the connecting step includes defining a hermetic seal.

29. 1. A method for manufacturing a structural element, comprising: subjecting a surface of a non-metallic substrate to an oven-free, vacuum chamber-free metal deposition process that includes a friction surface treatment to form a metal layer on the substrate, the metal layer defining a coating on the substrate; connecting a metal foil to the metal layer; A method having the following.

30. a non-metallic substrate including a metal layer on at least a portion of the substrate, the non-metallic substrate being formed using a friction surface treatment process; a metal foil attached to the substrate via the metal layer; A structural element, characterized in that the frictional surface treatment process comprises subjecting at least one surface of the substrate to an oven-free, vacuum chamber-free metal deposition process.

31. 1. A method for manufacturing a structural element, comprising:

1. A method comprising: subjecting a surface of a non-metallic substrate to an oven-free, vacuum chamber-free metal deposition process including a frictional surface treatment to form a metal layer on at least a portion of the substrate, the metal layer defining a coating on the substrate.

32. 32. The method of claim 31, wherein the non-metallic substrate comprises a vehicle window and the metal layer is formed in a line extending along the length or width of the vehicle window.

Images