Optical Bonding Layer Structure for Atmospheric Diffusion Joining
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Solution Overview
Problem
Existing atomic diffusion bonding methods are costly and require expensive ultrahigh vacuum facilities and long processing times, limiting their application in optical parts like lenses and prisms, which demand light resistance and precise alignment.
Innovation Solution
A structure and method involving a bonding layer with specific metal elements, where a first metal element with high self-diffusion coefficient and free energy of oxide formation is combined with a second metal element having lower free energy of oxide formation, using an oxygen supply layer to oxidize and diffuse the second metal element, enabling bonding in the atmosphere and improving alignment properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If atomic diffusion bonding is performed using conventional methods with metal bonding films, then bonding strength is achieved, but the process requires expensive ultrahigh vacuum facilities and long processing times
Solution Approach 1:
The patent introduces an oxygen supply layer as an intermediary component between the bases and bonding films. This layer supplies oxygen during bonding to promote oxide formation at the interface, enabling atomic diffusion bonding to proceed in atmospheric conditions rather than requiring ultrahigh vacuum facilities. The oxygen supply layer acts as a mediator that facilitates the bonding reaction without the need for complex vacuum equipment.
Solution Approach 2:
The patent changes the chemical environment parameters by introducing oxygen through the oxygen supply layer. This allows the bonding process to occur in atmospheric conditions with controlled oxygen availability, transforming the bonding mechanism to work under simpler environmental conditions while maintaining bonding strength through controlled oxide formation at the interface.
2Reliability
If atomic diffusion bonding is performed using conventional methods, then bonding is achieved, but processing time is extended
Solution Approach 1:
The oxygen supply layer is prepared in advance on the base surfaces before bonding. This preliminary provision of oxygen sources allows the bonding reaction to proceed more rapidly once heating begins, as oxygen is already available at the bonding interface rather than needing to be introduced during the process, thereby reducing overall processing time while ensuring bonding achievement.
3Reliability
If conventional bonding methods are used for optical parts, then bonding is achieved, but alignment properties deteriorate
Solution Approach 1:
The oxygen supply layer serves as a mediator that enables atmospheric bonding, which in turn allows for the implementation of alignment procedures. Since the bonding can occur in atmospheric conditions, alignment can be performed using conventional optical alignment techniques before bonding, improving manufacturing precision without compromising bonding achievement.
4Reliability
If bonding films are formed on smooth surfaces, then bonding is achieved, but light resistance deteriorates
Solution Approach 1:
The patent applies different properties to different regions: the oxygen supply layer is positioned only at the bonding interface to supply oxygen for bonding, while the bonding films are made as thin as possible and positioned only where needed for bonding. This localized application allows bonding achievement at the interface while maintaining light resistance in the optical paths, as the bonding structures are confined to minimal regions.
Solution Approach 2:
The patent changes the optical parameters by making bonding films extremely thin and confining bonding structures to minimal regions. This parameter optimization allows the bonding interface to achieve sufficient bonding strength through controlled oxide formation, while the thin film structures minimize light absorption and scattering, thereby maintaining light resistance for optical applications.
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 reduces costs, eliminates the need for ultrahigh vacuum facilities, allows for faster bonding, and enhances alignment accuracy and durability of optical parts by creating a transparent bonding layer.
Implementation Method 1
the second metal element is oxidized by oxygen released from the oxygen supply layer to transparentize the bonding layer
Implementation Method 2
replacement and diffusion occur between the second metal layer and the first metal layer
Data Source
AI summary
A structure according to an embodiment of the present disclosure include: a first base; a second base disposed to be opposed to the first base; and a bonding layer that is provided between the first base and the second base, and includes, in a layer, a layer including a first metal element and a second metal element, the first metal element having a free energy of oxide formation (ΔG) of −330 (kJ/mol of compounds) or more at room temperature and a self-diffusion coefficient (D) of 1×10−55 (m2/s) or more at room temperature, and the second metal element having a free energy of oxide formation (ΔG) at room temperature smaller than the free energy of oxide formation (ΔG) at the room temperature of the first metal element.