Pass-through Seal for Electro-optic Assembly Stress Reduction
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Solution Overview
Problem
Traditional methods of sealing electro-optic assemblies often result in pressurized and bowed substrates, leading to unnecessary stress and potential leaks due to poor plugging of non-compressible electro-optic media.
Innovation Solution
An electro-optic assembly design featuring a primary seal between substrates, a fill port, and a secondary seal forming a channel, where a fluid plug is used to solidify and seal the cavity, with a pass-through plug extending through openings and a deformable sealing material covering exposed portions to prevent leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing methods are used to seal the electro-optic assembly, then the assembly is enclosed, but the substrates become pressurized and bowed, creating unnecessary stress
Solution Approach 1:
The sealing system is divided into multiple components: a primary seal between substrates, a secondary seal proximate to the primary seal, and a plug material within a defined channel. This segmentation allows each component to perform its sealing function independently without transferring excessive stress to the substrates.
Solution Approach 2:
A channel is created between the primary and secondary seals to accommodate the plug material. This intermediary channel allows the sealing material to be contained and cured in a controlled space, preventing direct pressure transmission to the substrates while maintaining effective sealing.
2Reliability
If plugging material is forced into a single port of the cavity, then the cavity is sealed, but poor plugging and leaks occur due to the non-compressible electro-optic medium
Solution Approach 1:
The sealing process is divided into two stages: first, the primary seal is formed between the substrates to define the cavity; second, the secondary seal is added to create a channel that guides the plug material. This segmentation allows the plug material to be introduced and contained systematically, ensuring complete filling without leaks.
Solution Approach 2:
The channel structure between the primary and secondary seals automatically contains and directs the plug material during the sealing process. The geometry of the channel ensures that the plug material fills the intended space completely, eliminating the need for complex external tools or techniques to achieve proper plugging.
3Strength
If a rigid plug is used to seal the openings, then the seal is strong, but the plug cannot accommodate manufacturing tolerances and substrate variations
Solution Approach 1:
The plug material transitions from a soft, uncured state during insertion to a hardened, strong state after curing. This parameter change allows the material to be adaptable during the sealing process to accommodate tolerances, then provides structural strength once cured. The material's properties are dynamically adjusted through the curing process.
Solution Approach 2:
The sealing system uses a composite approach combining the primary seal, secondary seal, and plug material with different properties. The plug material itself may have composite characteristics, combining initial deformability for adaptability with final hardness for strength, creating a multi-property sealing solution.
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 design effectively seals the electro-optic assembly, reducing stress on the substrates and preventing leaks by using a solidifying plug and deformable sealing material, ensuring a reliable and secure enclosure for the electro-optic medium.
Implementation Method 1
The sealing plug material may comprise an initially fluid material. The sealing plug material may be capable of hardening to form a solid plug.
Implementation Method 2
The sealing material may be initially deformable. The sealing material may be disposed to cover exposed portions of the head and the second end of the plug.
Data Source
AI summary
An electro-optic assembly includes a first substrate and a second substrate. A primary seal is disposed between the first substrate and the second substrate. The primary seal, the first substrate, and the second substrate define an interior cavity. A fill port extends through the primary seal. A secondary seal is disposed proximate a side of the primary seal. The primary seal and the secondary seal define a channel. A sealing plug is disposed within the channel.