Interlocking Ceramic and Optical Members for Sealing
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Solution Overview
Problem
Conventional methods for inserting optical members into ceramic housings often result in weak mechanical integrity and unsatisfactory environmental permeability, leading to potential water or debris ingress, and may require additional structures like bezels that increase device size and weight.
Innovation Solution
An interlocking ceramic housing with a recessed geometry that mechanically interlocks with an optical member, where the housing and optical member have corresponding geometries, and the optical member is compression-loaded after sintering, optionally with a bonding agent like zirconia or ceramic slurry to enhance sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives or bonding agents are used to insert optical members into ceramic housing, then mechanical integrity is improved, but environmental permeability deteriorates (increased risk of water or debris ingress)
Solution Approach 1:
The patent removes the optical member from the ceramic housing after sintering, eliminating the need for adhesives or bonding agents. The optical member is inserted into a recess in the ceramic housing before sintering, and the differential thermal contraction creates a mechanical interference fit that provides both mechanical integrity and environmental sealing without additional bonding materials.
Solution Approach 2:
The patent utilizes parameter changes during the sintering process, specifically the differential thermal expansion/contraction between the ceramic housing and optical member. The ceramic housing has a higher coefficient of thermal expansion than the optical member, causing the recess to shrink relative to the optical member during cooling, creating a tight mechanical fit that ensures both structural strength and environmental permeability.
2Reliability
If bezels or additional structures are used to improve environmental sealing, then environmental permeability is improved, but device size and weight increase
Solution Approach 1:
The patent eliminates the need for bezels or additional sealing structures by integrating the sealing function directly into the ceramic housing-optical member interface. The differential thermal contraction creates a self-contained mechanical interference fit that provides environmental sealing without requiring separate bezel components.
Solution Approach 2:
The patent merges the mechanical support and environmental sealing functions into a single integrated structure. The ceramic housing recess and optical member geometry are designed to work together as a unified system, where the interference fit simultaneously provides structural support and environmental sealing, eliminating the need for separate bezel components.
3Ease of manufacture
If conventional insertion methods are used, then ease of manufacture is improved, but mechanical strength deteriorates (weak region around optical member)
Solution Approach 1:
The patent performs preliminary action by inserting the optical member into the ceramic housing recess before the sintering process. This allows the differential thermal contraction during sintering and cooling to automatically create the mechanical interference fit, eliminating the need for post-sintering insertion methods that would require adhesives or complex assembly steps.
Solution Approach 2:
The patent utilizes parameter changes during sintering, specifically the temperature-dependent dimensional changes of the ceramic housing and optical member. The higher coefficient of thermal expansion of the ceramic causes the recess to shrink relative to the optical member during cooling, creating a strong mechanical interference fit that eliminates weak regions around the optical member.
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 solution provides enhanced mechanical strength, reduced risk of water or debris ingress, and a more compact design without the need for additional structures, while maintaining the desirable properties of ceramic materials.
Implementation Method 1
sintering the ceramic housing to reduce the size of said recess
Implementation Method 2
the ceramic housing may have a higher coefficient of thermal expansion than the optical member
Data Source
AI summary
Interlocking first member and optical members and methods of their manufacture. A component formed from an interlocking first member and optical member, where the first member includes a recess formed within a surface and the optical member is disposed in the recess. The recess of the first member may include a recess geometry and the optical member may include a member geometry that may correspond to the recess geometry. Additionally, the interlocking component formed from the first member and optical member may be formed by a coupling process. The coupling process may include sintering the first member and the optical member, bonding the optical member to the first member or providing a compression-load or fit between the first member and the optical member.