INSULATED GLAZING UNITS AND METHODS

• US 20060191215A1
• Filed: 05/04/2006
• Published: 08/31/2006
• Est. Priority Date: 03/22/2002
• Status: Abandoned Application

• Current Assignee: Astravac Glass, Inc.
• Original Assignee: Astravac Glass, Inc.
• Inventors: Stark, David H.
• Application Number:
  US11/381,742
• Publication Number:
  US 20060191215A1
• Time in Patent Office: Days
• US Class Current: 52/204.6
• CPC Class Codes: C03C 27/08 with the aid of intervening metal
• CPC Class Codes: E06B 3/66342 characterised by their sealed connection to the panes
• CPC Class Codes: H01L 21/50 Assembly of semiconductor devices using processes or apparatus not provided for in a single one of the subgroups H01L21/06 - H01L21/326, e.g. sealing of a cap to a base of a container
• CPC Class Codes: H01L 23/10 characterised by the material or arrangement of seals between parts, e.g. between cap and base of the container or between leads and walls of the container
• CPC Class Codes: H01L 27/14618 Containers
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00

Abstract

A method for manufacturing a hermetically sealed window assembly. A first windowpane is provided, as is a first sealing member having inner and outer edges. The inner edge is positioned against the windowpane and pressed against it with sufficient force to produce a first contact pressure along a first junction. The junction is heated to produce a first temperature. The contact pressure and temperature are maintained until a diffusion bond is formed between the member and the windowpane. A second windowpane is provided, as is a second sealing member having inner and outer edges. The inner edge is positioned against the windowpane and pressed against it with sufficient force to produce a second contact pressure along a second junction. The junction is heated to produce a second temperature. The contact pressure and temperature are maintained until a diffusion bond is formed between the member and the windowpane. A spacer assembly is positioned between the first and second windowpanes for maintaining a gap therebetween. The outer ends of the sealing members are hermetically connected to one another, whereby a hermetically sealed cavity is defined between the windowpanes.

Claims

1. A method for manufacturing a hermetically sealed multi-pane window assembly, the method comprising the following steps:

providing a first windowpane sheet formed of a transparent material and having a periphery and a first sealing member having an inner edge and an outer edge;

positioning the inner edge of the first sealing member around the periphery of the first windowpane sheet;

pressing the inner edge of the first sealing member against the first windowpane sheet with sufficient force to produce a first predetermined contact pressure between the inner edge and the windowpane sheet along a first junction region;

heating the first junction region to produce a first predetermined temperature along the first junction region;

maintaining the first predetermined contact pressure and an elevated temperature until a diffusion bond is formed between the first sealing member and the first windowpane sheet around the periphery of the first windowpane sheet;

providing a second windowpane sheet formed of a transparent material and having a periphery and a second sealing member having an inner edge and an outer edge;

positioning the inner edge of the second sealing member around the periphery of the second windowpane sheet;

pressing the inner edge of the second sealing member against the second windowpane sheet with sufficient force to produce a second predetermined contact pressure between the inner edge and the windowpane sheet along a second junction region;

heating the second junction region to produce a second predetermined temperature along the second junction region;

maintaining the second predetermined contact pressure and an elevated temperature until a diffusion bond is formed between the second sealing member and the second windowpane sheet around the periphery of the second windowpane sheet; and

hermetically connecting the outer edge of the first sealing member to the outer edge of the second sealing member, whereby a hermetically sealed cavity is defined between the first and the second windowpanes.

2. A method for manufacturing a window assembly in accordance with claim 1, further comprising, before the step of hermetically connecting the outer edge of the first sealing member to the outer edge of the second sealing member, the step of positioning a spacer assembly between the first and the second windowpane sheets for maintaining a gap therebetween.

3. A method for manufacturing a window assembly in accordance with claim 1, wherein the first and second sealing members are sealed together while in a vacuum environment.

4. A method for manufacturing a window assembly in accordance with claim 1, further comprising the step of evacuating the hermetically sealed cavity between the first and the second windowpanes to produce a vacuum after the first and second sealing members are sealed together.

5. A method for manufacturing a window assembly in accordance with claim 1, further comprising the step of filling the hermetically sealed cavity between the first and the second windowpanes with a gas after the first and second sealing members are sealed together.

6. A method of manufacturing a hermetically sealed multi-pane window assembly, the method comprising the steps:

providing a first windowpane formed of a transparent material and having a periphery;

providing a first sealing member having an inner edge and an outer edge;

hermetically sealing the inner edge of the first sealing member to the first windowpane around the periphery;

providing a second windowpane formed of a transparent material and having a periphery, the second windowpane being spaced-apart from the first windowpane;

providing a second sealing member having an inner edge and an outer edge;

hermetically sealing the inner edge of the second sealing member to the second windowpane around the periphery;

hermetically sealing the outer edge of the second sealing member to the outer edge of the first sealing member; and

at least one of the first and second sealing members being compliant to enable relative movement between the first and second windowpanes;

whereby a hermetically sealed cavity is formed between the first and the second windowpanes.

7. A method in accordance with claim 6, wherein at least one of the steps of hermetically sealing comprises a diffusion bonding process.

8. A method in accordance with claim 7, wherein the diffusion bonding process includes a solid-state diffusion bonding process that includes holding the windowpane and sealing member together with a specified surface pressure for a specified length of time at a specified elevated temperature, the elevated temperature being lower than the melting point of either of the windowpane and sealing member.

9. A method in accordance with claim 8, further comprising positioning an interlayer material between the first windowpane and the first sealing member prior to diffusion bonding.

10. A method in accordance with claim 6, wherein the diffusion bonding process includes transient liquid-phase diffusion bonding having an initial elevated temperature sufficient to melt a bonding material on one of either the windowpane and sealing member, and a subsequent elevated temperature, lower than the initial temperature, that allows solidification of the bonding material, the subsequent elevated temperature being maintained until the bonding material diffuses into the parent materials by solid-state diffusion.

11. A method in accordance with claim 10, further comprising positioning an interlayer material between the first windowpane and the first sealing member prior to diffusion bonding.

12. A window assembly in accordance with claim 6, wherein at least one of the steps of hermetically sealing comprises a soldering process.

13. A method in accordance with claim 12, wherein the soldering process utilizes a solder glass material.