Stack Sealed Glass Articles with Hydroxyl Uniformity

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Solution Overview

Problem

Existing methods for forming glass articles are limited by the size of glass articles formed, due to furnace size or technical limits, and result in non-homogeneous glass articles across the interface when stack sealing multiple substrates, leading to temperature non-uniformity and optical performance issues.

Innovation Solution

A method of forming glass articles by positioning two glass substrates with their interface surfaces facing each other, and then heating them in a sealing environment at a sufficient temperature and time to stack seal them, achieving improved hydroxyl group concentration uniformity across the interface, which enhances thermal stability and optical performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If glass substrates are stack sealed to form larger glass articles, then the size of glass articles is increased, but the hydroxyl group concentration uniformity across the interface deteriorates

Engineering Contradiction:

Improvesize of glass articlesVSAvoidhydroxyl group concentration uniformity

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The glass substrates are pre-prepared with controlled hydroxyl group concentrations and positioned with precisely controlled spacing (0-5 mm) between interface surfaces before sealing. This preliminary preparation ensures that when the substrates are stack sealed, the hydroxyl group concentration uniformity is maintained across the interface, resolving the contradiction between increasing glass article size and maintaining manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent controls specific parameters including the spacing between interface surfaces (0-5 mm), sealing temperature, and sealing time to optimize the diffusion and distribution of hydroxyl groups during the stack sealing process. By carefully adjusting these parameters, the hydroxyl group concentration uniformity is improved across the interface even when forming larger glass articles through substrate stacking.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If conventional stack sealing methods are used, then glass articles can be formed, but temperature non-uniformity occurs leading to optical performance issues

Engineering Contradiction:

Improveglass article formationVSAvoidoptical performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies different hydroxyl group concentrations to different regions of the glass substrates, specifically controlling the concentration at the interface regions versus the bulk regions. This local quality control ensures that the interface areas have optimized hydroxyl group concentrations for thermal stability, while the bulk regions maintain their structural properties, thereby improving optical performance without compromising ease of manufacture.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements a controlled sealing process where the spacing between substrates, temperature, and time are optimized based on feedback from the desired hydroxyl group distribution. This feedback-controlled process ensures uniform temperature distribution and hydroxyl group concentration during sealing, preventing optical performance issues while maintaining manufacturing feasibility.

Inventive Principle:

Principle #23Feedback

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 method achieves a peak-to-valley difference of hydroxyl group concentration of less than or equal to 30 ppm, ensuring increased thermal stability and maintaining surface shape under temperature changes, thereby improving the optical performance of the glass articles.

Implementation Method 1

heating the glass article precursor in a sealing environment at a sealing temperature and for a time sufficient to stack seal the first glass substrate to the second glass substrate... improved hydroxyl group concentration uniformity across the interface

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

heating the glass article precursor in a sealing environment at a sealing temperature and for a time sufficient to stack seal the first glass substrate to the second glass substrate

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20250171345A1Glass articles with increased hydroxyl group uniformity comprising stack sealed glass substrates, and methods of forming the same

Publication Date: 2025.05.29 CORNING INC

AI summary

A method of forming a glass article includes positioning a first glass substrate and a second glass substrate with a first interface surface of the first glass substrate facing a second interface surface of the second glass substrate to produce a glass article precursor, and heating the glass article precursor in a sealing environment to stack seal the first glass substrate to the second glass substrate to form the glass article. Subsequent to the heating, the second interface surface and the first interface surface are in direct contact with one another, establishing an interface between the first glass substrate and the second glass substrate.