Integrally Bonding Glass to Ceramic via Heated Contact Element

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Solution Overview

Problem

Existing methods for bonding glass elements to carrier elements, such as in optical devices, often suffer from instability due to material combinations and the use of adhesive layers, which can lead to component failure over time.

Innovation Solution

A method of integrally bonding a glass element to a carrier element using a contact element inserted into a contact recess on the carrier element, followed by local heating to create a material bond without the use of adhesives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive layers are used to bond glass elements to carrier elements, then bonding is achieved, but component failure occurs due to ageing

Engineering Contradiction:

Improvebonding stabilityVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The invention extracts and eliminates the adhesive layer from the bonding system. Instead of using adhesives to bond the glass element to the carrier element, the patent uses a contact element that is inserted into a contact recess and locally heated to create a direct material bond, thereby removing the source of ageing-related failure.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The contact element serves as an intermediary component between the glass element and the carrier element. It is inserted into a contact recess in the carrier element and locally heated to create a material bond, mediating the connection without requiring adhesive layers that are prone to ageing.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If direct welding is used to connect glass with very low coefficient of thermal expansion to Si/SiC ceramics, then bonding is achieved, but carbon monoxide and carbon dioxide formation occurs

Engineering Contradiction:

Improvebonding strengthVSAvoidgas formation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The contact element acts as an intermediary that prevents direct contact and reaction between the glass element and the Si/SiC ceramic carrier element. By inserting the contact element into a contact recess and locally heating it, a material bond is created without direct welding of glass to ceramic, thereby avoiding carbon monoxide and carbon dioxide formation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The bonding interface is segmented into three distinct components: the glass element, the contact element, and the carrier element. This segmentation prevents direct harmful reactions between glass and Si/SiC ceramic while maintaining bonding strength through the intermediate contact element.

Inventive Principle:

Principle #1Segmentation

3Shape

If adhesive-free connection is used to maintain flat surface, then surface flatness is achieved, but bonding strength may be compromised

Engineering Contradiction:

Improvesurface flatnessVSAvoidbonding strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The invention replaces mechanical adhesive bonding with a thermally-induced material bond. By locally heating the contact element to its melting temperature, the softened material creates a strong material bond between the glass element and carrier element without requiring adhesive layers, thereby maintaining surface flatness while ensuring bonding strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method achieves a strong, adhesive-free connection between glass and ceramic elements, ensuring stability even under temperature fluctuations, and is suitable for high-precision applications like optical devices.

Implementation Method 1

melted material from the contact element can wet the glass element to create a connection in the sense of a soldering process

Methodology Applied

Scientific EffectWetting: Wetting

Implementation Method 2

the contact element can be heated above its melting temperature, wherein the softened glass can wet the carrier element or the barrier layer covering the carrier element

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

create a connection in the sense of a soldering process

Methodology Applied

Scientific EffectSoldering: Soldering

Implementation Method 4

create a connection in the sense of a welding process

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 5

connect the glass element to the carrier element via the contact element

Methodology Applied

Scientific EffectMaterial bond: Chemical Bonding

Data Source

PatentUS12338183B2Method for integrally bonding a glass element to a support element, and optical device

Publication Date: 2025.06.24 JENOPTIK OPTICAL SYSTEMS GMBH

AI summary

A method of integrally bonding a glass element to a support element, the method comprising a step of inserting at least one contact element into a contact recess in a surface of the support element. In addition, the method comprises a step of placing the glass element on a portion of the contact element which portion protrudes beyond the surface, and a step of locally heating the contact element in order to connect the glass element to the carrier element via the contact element. The method also comprises a step of coating at least a part of the contact recess with a separating layer prior to the step of insertion.