Metal Injection Molded Glass Seal with Rough Texture
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Solution Overview
Problem
Glass-to-metal seals face challenges in achieving and maintaining a hermetic joint over long time spans due to the distinct chemical and mechanical properties of metals and glass, and CNC machining for complex features is costly.
Innovation Solution
A component with a base body and a glass element, where the glass is fused into an opening with a rough, aperiodic texture, forming a firm anchoring and hermetic seal, potentially enhanced by a substance-to-substance bond and a compressive seal achieved through differing thermal expansion coefficients, and a metal oxide layer for a chemical bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If CNC machining is used for complex features, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces mechanical CNC machining with an injection molding process that uses a textured mold cavity to create complex surface features. The mold texture directly imprints the complex geometry onto the base body during molding, eliminating the need for subsequent costly CNC machining operations while maintaining manufacturing precision for complex features.
2Reliability
If a hermetic joint between metal and glass is achieved, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent changes the surface energy parameters of the metal base body by applying a textured surface treatment that increases surface roughness. This parameter change enables the glass to form a hermetic bond with the metal through mechanical interlocking and increased surface area contact, achieving reliable sealing without complex additional manufacturing steps.
Solution Approach 2:
The patent creates a composite interface structure where the glass element bonds to the textured metal surface, forming a hybrid joint that combines the hermetic properties of glass-to-glass sealing with the structural advantages of metal. This composite approach simplifies the overall manufacturing process while maintaining seal integrity.
3Ease of manufacture
If the base body has porosity from injection molding, then ease of manufacture is improved, but hermeticity worsens
Solution Approach 1:
The patent applies local quality by creating a textured surface layer on the base body that specifically addresses the sealing interface area. The texture is concentrated at the bonding surface where hermeticity is critical, while the bulk material can retain the porosity inherent to injection molding. This localized treatment ensures hermetic sealing without requiring the entire base body to be dense.
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
The solution provides a robust and hermetic seal with complex designs achievable at lower costs, maintaining integrity over time despite porosity in the base body, suitable for sensitive components requiring moisture and dust protection.
Implementation Method 1
the glass of the element is fused into an opening (7) with a rough, aperiodic texture so as to form a firm anchoring
Implementation Method 2
the glass closely approximates the surface of the wall, or, in other words wets the surface of the wall so that protrusions and voids at the wall are in contact with the glass
Implementation Method 3
the interface between the glass of the element and the base body may constitute a substance-to-substance bond, or a chemical bond, respectively, to further enhance the hermeticity of the seal
Implementation Method 4
a metal oxide layer for a chemical bond
Data Source
Figure 1~4
Figure 5~6
Figure 7(a)~7(b)
AI summary
A component (1) with a base body (3) and a glass element (5), the glass element (5) being seated in an opening (7) of the base body (3), wherein the base body (3) is a metal injection molded element so that the wall (9) of the opening (7) has an uneven, rough texture, and wherein the glass of the glass element (5) is fused into the opening (7) so that the glass closely approximates the surface of the wall (9) and hermetically seals the opening. (7).