Batch Optical Window Production for Hermetic Sealing
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Solution Overview
Problem
The high cost and labor-intensive process of producing individual optical MEMS windows for microdevices, which are necessary for both optical access and protection from environmental contamination, leads to increased overall device costs due to the need for multiple steps in manufacturing each separate window.
Innovation Solution
Implementing a batch processing technique that allows for the simultaneous production of multiple windows by stamping metal frames and fusing them with a large sheet of glass, followed by polishing and coating, which reduces the number of steps required and eliminates individual glass rounding and metal window frame machining, enabling economies of scale and lower per-unit costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual windows are manufactured using traditional methods with multiple steps including glass rounding and metal frame machining, then the windows provide high quality hermetic sealing and optical performance, but the production cost and labor intensity increase significantly
Solution Approach 1:
The patent combines multiple traditional manufacturing steps into a single integrated process. Specifically, the metal frame is stamped with the aperture and lip in one operation, and the glass is fused to the metal frame without requiring separate glass rounding or frame machining steps. This merging of operations maintains hermetic sealing quality while dramatically reducing manufacturing complexity and labor requirements.
Solution Approach 2:
The patent segments the manufacturing process by eliminating unnecessary intermediate steps. Instead of performing glass rounding, metal frame machining, and assembly as separate operations, the process is segmented to only include stamping the metal frame with the aperture and lip, followed by direct glass fusion. This selective segmentation removes non-essential steps while preserving the critical hermetic sealing function.
2Productivity
If batch processing techniques are used to produce multiple windows simultaneously, then production efficiency increases and per-unit cost decreases, but the complexity of coordinating simultaneous processing of multiple frames and glass sheets increases
Solution Approach 1:
The patent merges multiple windows into a single batch processing operation. Multiple metal frames are stamped simultaneously from a single sheet, and multiple glass sheets are fused to multiple frames in one heating cycle. This merging approach increases productivity by producing multiple windows concurrently while the standardized process design keeps coordination complexity manageable.
Solution Approach 2:
The patent creates a universal processing system that can handle multiple windows of the same configuration simultaneously. The stamping die and fusion process are designed to accommodate multiple frames and glass sheets in a standardized arrangement, making the process multi-functional for batch production while maintaining consistent quality across all units.
3Reliability
If glass is fused to metal frames using traditional methods, then hermetic sealing is achieved, but the heat from fusing ruins the glass surface finish requiring additional grinding and polishing steps
Solution Approach 1:
The patent applies preliminary action by performing the glass fusion process in a way that preserves surface finish. The metal frames are designed with lips that position the glass at a distance from the heating elements during fusion, and the fusion temperature and duration are controlled to achieve hermetic sealing without excessive heat exposure that would damage the glass surface. This preliminary consideration of surface protection during process design eliminates the need for subsequent grinding and polishing steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces production time and labor, lowers the cost of each window, and maintains the necessary optical and hermetic qualities, while ensuring effective mounting on microdevice packages with a metal-only frame for welding, thereby improving manufacturing efficiency and reducing device costs.
Implementation Method 1
Glass is then fused to the metal frame in order to form the overall window structure
Data Source
AI summary
Disclosed embodiments demonstrate batch processing methods for producing optical windows for microdevices. The windows protect the active elements of the microdevice from contaminants, while allowing light to pass into and out of the hermetically sealed microdevice package. Windows may be batch produced, reducing the cost of production, by fusing multiple metal frames to a single sheet of glass. In order to allow windows to be welded atop packages, disclosed embodiments keep a lip of metal without any glass after the metal frames are fused to the sheet of glass. Several techniques may accomplish this goal, including grinding grooves in the glass to provide a gap that prevents fusion of the glass to the metal frames along the outside edges in order to form a lip. The disclosed batch processing techniques may allow for more efficient window production, taking advantage of the economy of scale.