U.S. patent application number 13/795116 was filed with the patent office on 2013-09-12 for high performance organic, inorganic or hybrid seals.
This patent application is currently assigned to FERRO CORPORATION. The applicant listed for this patent is FERRO CORPORATION. Invention is credited to Vineet Dua, Chandrashekhar S. Khadilkar, George E. Sakoske, Srinivasan Sridharan.
Application Number | 20130236662 13/795116 |
Document ID | / |
Family ID | 49114357 |
Filed Date | 2013-09-12 |
United States Patent
Application |
20130236662 |
Kind Code |
A1 |
Dua; Vineet ; et
al. |
September 12, 2013 |
High Performance Organic, Inorganic Or Hybrid Seals
Abstract
The present invention describes a new method for creating hybrid
edge seals using metal, alloy, powder coated metal and other
conductive surfaces in between two substrates. The methods utilize
various materials, seal designs, and geometries of hybrid seals
based on polymeric powder coatings and glass powder coatings.
Inventors: |
Dua; Vineet; (Parma Heights,
OH) ; Khadilkar; Chandrashekhar S.; (Broadview
Heights, OH) ; Sridharan; Srinivasan; (Strongsville,
OH) ; Sakoske; George E.; (Independence, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FERRO CORPORATION |
Mayfield Heights |
OH |
US |
|
|
Assignee: |
FERRO CORPORATION
Mayfield Heights
OH
|
Family ID: |
49114357 |
Appl. No.: |
13/795116 |
Filed: |
March 12, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61609414 |
Mar 12, 2012 |
|
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Current U.S.
Class: |
428/34 ;
156/272.4; 156/272.8; 156/60; 228/248.1; 428/76; 428/77; 65/43 |
Current CPC
Class: |
B23K 35/3613 20130101;
Y10T 428/239 20150115; B23K 35/365 20130101; Y10T 156/10 20150115;
B23K 35/0244 20130101; B32B 7/04 20130101; C03C 27/08 20130101;
B32B 2457/00 20130101; B32B 37/12 20130101; C03C 27/04 20130101;
C03C 27/10 20130101; B23K 35/22 20130101 |
Class at
Publication: |
428/34 ; 156/60;
156/272.4; 156/272.8; 228/248.1; 65/43; 428/76; 428/77 |
International
Class: |
B32B 7/04 20060101
B32B007/04; B23K 35/22 20060101 B23K035/22; C03C 27/04 20060101
C03C027/04; B32B 37/12 20060101 B32B037/12 |
Claims
1. A method of locally heating a sealing material to produce a
seal, comprising: a. providing a metal object between at least two
substrates; b. providing a seal material, c. contacting the seal
material to the at least two substrates and at least partially
surrounding the metal object, and d. heating the metal object to
heat the seal material to a temperature of at least 125.degree. C.,
wherein the substrate temperature remains at least 20.degree. C.
below the temperature attained in the seal, to flow the seal
material between the substrates, whereby a seal between the
substrates results.
2. The method of claim 1, wherein the seal is hermetic.
3. The method of claim 1, wherein the seal material is at least one
selected from the group consisting of: a. organic, b. inorganic, c.
hybrid, and d. glasses having a melting point less than 600.degree.
C.
4. The method of claim 3, wherein the seal material includes at
least one glass having a melting point less than 600.degree. C.
selected from the group consisting of vanadate glasses, lead based
glasses, tin glasses, phosphate glasses, borate glasses, bismuth
glasses, thallate glasses, and Sn--Zn--P glasses.
5. The method of claim 1, wherein prior to (c) at least one of the
metal object and the seal material is preheated by laser or
induction heating.
6. The method of claim 1, wherein the at least two substrates are
independently selected from the group consisting of metal, glass,
very low expansion glass ceramics, ceramics, low expansion
borosilicate glass, aluminosilicate glass, ion-exchanged sodium
aluminosilicate glass, potassium exchanged aluminosilicate glass
chemically strengthened glass, tempered glass, surface strengthened
metal coated glass, conductive substrates, conductive oxides,
indium tin oxide, fluorinated tin oxide, transparent conductive
oxides.
7. The method of claim 8, wherein at least one substrate is metal
coated glass, wherein at least one metal selected from the group
consisting of silver, copper, tin, and aluminum is applied to a
glass plate in a pattern selected from the group consisting of full
covering, partial covering, and conductive traces.
8. The method of claim 1, wherein the metal object is a wire.
9. The method of claim 1, wherein the metal object is a sheet of
metal having a thickness, optionally including a cut-out
portion.
10. The method of claim 9, wherein an active layer is provided in a
cavity formed by the cut out portion and the substrates.
11. The method of claim 1, wherein the a cavity is formed by the
substrates, the metal object and the seal, and wherein the cavity
houses a device is selected from the group consisting of vacuum
insulated glass, solar cell contact, solar cell, solar cell module,
organic PV device, plasma display device, nanocrystal display,
electrochromic device, electrochromic material system, sensors,
suspended particle device, micro-blind, liquid crystal device,
smart window, switchable window, smart glass, eglass, quantum dot
devices, thermolelectric devices, batteries, LED, SED, FED, OLED,
LCD, DLP, FLD, IMOD, TDEL, QDLED, TMOS, TPD, LCL, LPD, OLET, and
combinations thereof.
12. The method of claim 1, wherein the metal object is at least
partially coated with a powder coating selected from the group
consisting of thermoplastics, thermosets, ionomer resins,
polyethylene, polypropylene, polystyrene, polyvinyl chloride, HDPE,
LDPE polytetrafluoroethylene, acrylics, PMMA, silicones,
polyesters, epoxies, epoxypolyesters, polyurethanes, halogenated
plastics, condensation plastics, polyaddition plastics,
cross-linking plastics, fluoropolymers, PTFE, polyamides,
polycarbonates, nylons, natural rubber, styrene-butadiene rubber,
PVB, PI, SRP, TPI, PAI, HTS, PFSA, PEEK, PPSU, PEI, PESU, PSU, LCP,
PARA, HPN, PPS, PPA, PC, PPC, COC, ABS, PVC Alloys, PEX, PVDC, PBT,
ET, POM, glycidyl methacrylate, and triglycidyl isocyanurate.
13. The method of claim 1, wherein at least one substrate is
selected from the group consisting of metal, metal coated glass,
conductive substrates and conductive oxides, wherein (b) includes
applying a powder coating to the metal object using a mask.
14. The method of claim 1, wherein at least one substrate is a
ceramic.
15. The method of claim 1, wherein at least one substrate is a
glass-ceramic.
16. The method of claim 1, wherein the metal object includes a
metal selected from the group consisting of aluminum; aluminum
alloys including AL1050, AL1060, AL1100, AL3003, AL6063, AL5052,
AL514, AL6061, AL384, AL2024; copper, nickel, iron, stainless
steel, 102 stainless steel, 201 stainless steel, 202 stainless
steel, 300 series stainless steel, 302 stainless steel, 304
stainless steel, 308 stainless steel, 309 stainless steel, 316
stainless steel, 321 stainless steel, 405 stainless steel, 408
stainless steel, 409 stainless steel, 410 stainless steel, 416
stainless steel, 420 stainless steel, 430 stainless steel, 439
stainless steel, 440 stainless steel, 446 stainless steel, 501
stainless steel, 502 stainless steel, 2205 stainless steel, 2304
stainless steel, 2507 stainless steel, 630 stainless steel, Ni--Fe
alloys, Ni--Cr alloys, chromium, molybdenum, tungsten, Invar,
Kovar, Alloy 36, and Alloy 42, Alloy 42-6, Alloy 48, Alloy 49,
Alloy 52, Alloy 600, Alloy 625, Inconel, Alloy 718, Nickel 200,
Nickel 201, Nickel 205, Nickel 233, Nickel 270, Tin, any of the
foregoing coated in a polymer, and alloys of any two or more of the
foregoing.
17. The method of claim 1 wherein the seal material is inorganic
particles distributed in a matrix of organic material.
18. The method of claim 17, wherein the inorganic particles are
selected from the group consisting of metal, glass, metal oxides,
silica, quartz, cements, inorganic polymers, mica sheets, mica
flakes, glass powders, Na--B--Si glass, B--Si glass, hygroscopic
inorganic additives, zeolites, molecular sieves, desiccant
materials, calcium chloride, calcium sulfate, magnesium chloride,
zinc chloride, potassium carbonate, potassium phosphate,
carnallite, ferric ammonium citrate, potassium hydroxide, and
sodium hydroxide, metal powders up to 5 microns, and metal flakes
up to 5 microns.
19. The method of claim 1, wherein the inorganic seal material is
selected from the group consisting of metal, glass, metal oxides,
silica, quartz, cements, inorganic polymers, mica sheets, mica
flakes, glass powders, Na--B--Si glass, B--Si glass, hygroscopic
inorganic additives, zeolites, molecular sieves, desiccant
materials, calcium chloride, calcium sulfate, magnesium chloride,
zinc chloride, potassium carbonate, potassium phosphate,
carnallite, ferric ammonium citrate, potassium hydroxide, and
sodium hydroxide, metal powders up to 5 microns, and metal flakes
up to 5 microns.
20. The method of claim 1, wherein providing a hybrid seal material
includes at least one of electrostatic deposition, powder coating,
spray coating, dip coating doctor blading, stenciling, and ink-jet
printing on at least one of the metal object and the
substrates.
21. A device including a seal made by the method of claim 1.
22. The method of claim 1, wherein the seal material is provided in
the form of a tape.
23. A device including a seal, the device formed by a method of
locally heating a sealing material comprising: a. providing a metal
object between at least two substrates; b. providing a seal
material between the two substrates and at least partially
surrounding the metal object, and c. heating the metal object to
heat the seal material to a temperature of at least 125.degree. C.,
wherein the substrate temperature remains at least 20.degree. C.
below the temperature attained in the seal, to flow the seal
material between the substrates.
24. The device of claim 23, wherein the device is selected from the
group consisting of vacuum insulated glass, solar cell contact,
solar cell, solar cell module, organic PV device, plasma display
device, nanocrystal display, electrochromic device, electrochromic
material system, sensors suspended particle device, micro-blind,
liquid crystal device, smart window, switchable window, smart
glass, eglass, quantum dot devices, thermolelectric devices,
batteries, LED, SED, FED, OLED, LCD, DLP, FLD, IMOD, TDEL, QDLED,
TMOS, TPD, LCL, LPD, OLET, and combinations thereof.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The invention describes a new method for creating hybrid
edge seals using metal, alloy, powder coated metal and other
conductive surfaces in between two substrates. These inventions
describe different materials, seal designs, and geometries of
hybrid seals based on polymeric powder coatings and glass powder
coatings on conductive surfaces.
[0003] 2. Description of Related Art
[0004] Many conventional heating methods suffer the problem of
overheating substrates in the effort to heat and flow a seal
material. Further much energy is wasted due to unwanted heating of
the entire mass of substrates. Therefore, selective sealing methods
wherein the seal material alone is heated are attractive from
energy saving point of view.
[0005] Laser sealing is a widely investigated selective sealing
process, among various selective heating processes such as laser
sealing, induction heating, microwave heating, broadband IR
(Infrared) lamp heating, and focused IR heating. Even in all these
selective heating methods unwanted heating of substrates does
occur. Conventional frit-based laser sealing processed involve
absorption of an Infra-Red (IR) laser light by an absorber such as
pigment or colored frit in the seal system. Accordingly, the IR
absorption (i.e., heating) occurs at the top interface--the
interface between a substrate and the seal material. Owing to the
thickness and mass of material to be heated, the amount of heat
supplied must be relatively high. Conventional laser sealing
processes involve absorption of IR radiation by an appropriate
pigment or colored frit in the sealant material. Deposited seals
are typically about 60% or less of their theoretical density before
melting/sintering. Therefore, significant dimensional changes are
to be expected during laser processing (or any related localized
energy deposition process) to form the seal. The process can be
time consuming because such a large mass of material must be
heated, which can be problematic. For example, conventional frit
based laser sealing material includes an organic binder which can
provide contamination within a cavity formed by the sealed
substrates from combustion of the binder upon heating. The
resulting seal may also have large voids and bubbles that could
reduce the strength of the seal. Since most of the heat is
generated at the substrate/seal material interface, it is more
likely that the seal material and the substrate plate may crack.
Similar problems arise in other selective sealing processes where
IR, visible or UV lights are used for sealing.
[0006] In many of the practically useful applications of glass to
glass sealing, such as encapsulation of solar cells (crystalline
silicon as well as thin film based cadmium telluride (CdTe), copper
indium gallium selenides (CIGS), polymeric, or flexible), OLED
packaging, displays, touch screens and Vacuum Insulated Glass (VIG)
window sealing, and architectural or automotive window sealing,
there exists a need to use tempered glasses in many instances.
Glasses lose their temper when heated above about 350.degree. C. in
conventional furnace firing of sealing glass materials. Therefore,
there exists a need to selectively heat the seal material alone and
to effect the bonding to the base glasses/substrates without
significantly heating the base glasses/substrates. Similarly there
exists a need to selectively heat the seal material alone and to
effect the bonding to the base glasses/or glass to metal seals
without significantly heating the base glasses.
[0007] Accordingly improvements are sought in selective sealing
processes.
BRIEF SUMMARY OF THE INVENTION
[0008] There is an urgent need for moisture barrier films and edge
seals for thin film, crystalline silicon solar cell modules,
optoelectronic devices (e.g., LEDs, OLEDS), displays (such as
plasma display panel (PDP) and Microdisplays), and vacuum insulated
glass windows (VIG) and assemblies. The lifespan of solar devices
could be increased by protecting it from moisture and oxygen
ingress which in turn will reduce the levelized cost of energy
(LCOE). Similarly the service life of VIG windows in providing
insulation of thermal conduction can be extended if the seals are
effectively impervious to moisture and gas.
[0009] In this invention the following is contemplated: (1) hybrid
edge seal using powder coating (polymeric and glass based) on
metals and other conductive surfaces, (2) localized curing of the
powder coatings using a conduction mechanism, and (3) minimizing
moisture and oxygen ingress by using metal/alloy spacer as bulk of
the edge seal.
[0010] An embodiment of the invention is a method of locally
heating a sealing material to produce a hermetic seal, comprising:
(a) providing a metal object between at least two substrates; (b)
providing a seal material, (c) contacting the seal material to the
at least two substrates and at least partially surrounding the
metal object, and (d) heating the metal object to heat the seal
material to a temperature of at least 125.degree. C., wherein the
substrate temperature remains at least 20.degree. C. below the
temperature attained in the seal, to flow the seal material between
the substrates, whereby a seal between the substrates results.
[0011] An embodiment of the invention is a device including a seal,
the device formed by a method of locally heating a sealing material
comprising: (a) providing a metal object between at least two
substrates; (b) providing a seal material between the two
substrates and at least partially surrounding the metal object, and
(c) heating the metal object to heat the seal material to a
temperature of at least 125.degree. C., wherein the substrate
temperature remains at least 20.degree. C. below the temperature
attained in the seal, to flow the seal material between the
substrates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exploded view of the components used in a
sealed object of the invention.
[0013] FIG. 2 is an exploded view of the components used in a
sealed object of the invention.
[0014] FIG. 3 depicts an embodiment of the invention including two
glass plates with a metal sheet sealed there between.
[0015] FIG. 4 depicts an embodiment of the invention having a metal
wire sealed between two glass plates.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention provides materials, seal designs,
geometries and process steps for making hermetic seals, and
simplifying the manufacture of hermetic seals which are used to
protect active layers of electronic devices such as solar cells,
LEDs, OLEDs, plasma display panels and the like.
[0017] A variety of substrates including those made of glass,
metal, ceramic, or plastics, as well as those constituting active
devices may be sealed together by this invention to create a
hermetic seal in devices such as display devices (flat panel
screens, LED screens, LCD screens, plasma display panels), organic
light emitting diodes (OLEDs), solar cells and solar cell panels,
and even windows for both architectural and automotive
applications. The substrates may be coated with a coating such as
conductive coated glass, indium tin oxide, aluminum doped zinc
oxide, sputtered metals, antireflective coatings, SiN.sub.X
coatings, Si.sub.3N.sub.4 coatings, conductive polymer coatings on
glass, and combinations thereof.
[0018] An embodiment of the invention is a method of locally
heating a sealing material to produce a seal, comprising: (a)
providing a metal object between at least two substrates; (b)
providing a seal material, (c) contacting the seal material to the
at least two substrates and at least partially surrounding the
metal object, and (d) heating the metal object to heat the seal
material to a temperature of at least 125.degree. C., wherein the
substrate temperature remains at least 20.degree. C. below the
temperature attained in the seal, to flow the seal material between
the substrates, whereby a seal between the substrates results.
[0019] An embodiment of the invention is a device including a seal,
the device formed by a method of locally heating a sealing material
comprising: (a) providing a metal object between at least two
substrates; (b) providing a seal material between the two
substrates and at least partially surrounding the metal object, and
(c) heating the metal object to heat the seal material to a
temperature of at least 125.degree. C., wherein the substrate
temperature remains at least 20.degree. C. below the temperature
attained in the seal, to flow the seal material between the
substrates.
[0020] This invention describes a durable powder coating technique
(with metal as a spacer) to use as a barrier coating material to
(a) increase moisture resistance of an edge seal, (b) engineer
glass-resin and metal-resin interface to obtain films with
excellent barrier properties, (c) formulate edge seals with
excellent moisture resistance to enhance the useful life of solar
and other active devices, (d) selectively heat metal/glass
interfaces through conduction of heat from thermal or induction
heating of metal far away from the glass; (this will reduce
manufacturing time and cost) as well as (e) significantly reduce
curing time using thermal conduction through metallic surface in
module manufacturing to reduce module costs.
[0021] The advantages of this approach include (a) use of polymer
chemistries besides EVA with excellent UV and outdoor stability by
use of a variety of powder coatings both polymeric and glass based,
(b) use of metal/alloy spacer to reduce moisture and oxygen
ingress, (c) use of proven deposition methods like electrostatic
deposition or wet deposition, (d) faster and localized curing by
simple use of conduction mechanism, (e) suitability of
time-temperature curing cycles for PV module manufacturing at
150.degree. C. for 1-10 minutes, (f) potential to formulate back
side film with desired reflective by using powder coated metal.
[0022] The seals may be hermetic, with a hermeticity as measured by
helium leak rate of less than 10.sup.-5 atm*cc*sec.sup.-1,
preferably less than 10.sup.-7 atm*cc*sec.sup.-1, more preferably
less than 10.sup.-8 atm*cc*sec.sup.-1.
[0023] The major components of the invention are set forth
hereinbelow.
[0024] Substrate.
[0025] The substrates can be, broadly speaking, glass, ceramic,
glass-ceramic, metal, or polymeric. They are independently
selected. Composite substrates are also suitable, for example
polymer matrix composites, polymer glass composites, metal matrix
composites, or ceramic matrix composites. In particular the
substrates may be any of metal, glass, glass-ceramics, very low
expansion glass ceramics, ceramics, window glass, low expansion
borosilicate glass Borofloat.RTM. 33 glass, aluminosilicate glass,
surface strengthened alkali aluminosilicate glass ion exchanged
alkali aluminosilicate glass (such as Corning Gorilla.RTM. Glass),
tempered glass, surface strengthened metal coated glass e.g. silver
layer for charging to powder coat, conductive substrates,
conductive oxides, indium tin oxide, fluorinated tin oxide,
transparent conductive oxides, coated substrates and conductive
polymers.
[0026] The substrates may have a coating. Exemplary coated
substrates include metal coated glass, wherein at least one metal
is selected from the group consisting of silver, copper, tin, and
aluminum is applied to a glass plate in a pattern selected from the
group consisting of full covering, partial covering, and conductive
traces.
[0027] Yet another embodiment of this invention involves at least
one glass plate being tempered.
[0028] Yet another embodiment of this invention is where at least
one glass plate is a prelaminated glass assembly.
[0029] Yet another embodiment of this invention includes at least
one glass plate being coated with conductive coatings such as
transparent conductive oxide (TCO) using indium-tin oxide (ITO)
material.
[0030] Seal.
[0031] The seal material can be organic, inorganic, a hybrid of
organic and inorganic, or glasses having a melting point less than
500.degree. C. In some instances the abbreviation "in/organic" will
be used to mean "organic and/or inorganic."
[0032] The hybrid sealant system could have inorganic materials
ratio in the range of 5-95 vol % based on the volume of organic
material, preferably 10-90 vol % more preferably 20-80 vol % even
more preferably 30-60 vol % organic material and 40-70 vol %
inorganic material.
[0033] Organic Seal Material.
[0034] The organic seal material can be any organic material that
is solid at or near room temperature most broadly thermoplastics
and thermosets. In a preferred embodiment, the organic seal
material is applied by electrostatic coating to the metal object.
In another preferred embodiment, the organic seal material is
applied by electrostatic application, powder coating, spray
coating, dip coating doctor blading, stenciling, or ink jet
printing on at least one of the metal object and the substrates. A
mask may be used.
[0035] Suitable organic materials include thermoplastics,
thermosets, ionomers, HDPE, LDPE, polyethylene, polypropylene,
polystyrene, polyvinyl chloride, polytetrafluoroethylene, acrylics,
PMMA, silicones, polyesters, epoxies, epoxypolyesters,
polyurethanes, halogenated plastics, condensation plastics,
polyaddition plastics, cross-linking plastics, fluoropolymers,
PTFE, polyamides, polycarbonates, nylons, natural rubber,
styrene-butadiene rubber, PVB, PI, SRP, TPI, PAI, HTS, PFSA, PEEK,
PPSU, PEI, PESU, PSU, LCP, PARA, HPN, PPS, PPA, PC, PPC, COC, ABS,
PVC Alloys, PEX, PVDC, PBT, ET, POM, glycidyl methacrylate (GMA),
or triglycidyl isocyanurate (TGIC). GMA acrylics are preferred.
[0036] Polyesters such as powder coatings sold by AkzoNobel under
the Interpon.RTM. trademark are suitable. For example any of the
following Interpon.RTM. branded products are suitable: AkzoNobel
158C121, AkzoNobel 4JC01QF, AkzoNobel 4LC01QF, AkzoNobel 4LC07QF,
AkzoNobel 8A200Q, AkzoNobel 8A201Q, AkzoNobel 8A2174, AkzoNobel
8A226A, AkzoNobel 8D200Q, AkzoNobel 8D 201Q, AkzoNobel 8D202Q;
AkzoNobel 8D203Q, AkzoNobel 8J200Q, AkzoNobel 8J201Q, AkzoNobel
8J202Q, AkzoNobel 8J203Q, AkzoNobel 8K200Q, AkzoNobel 8K201Q,
AkzoNobel 8K202Q, AkzoNobel 8K203Q, AkzoNobel 8K204K, AkzoNobel
8L200Q and other coatings sold under the Interpon name, and
combinations thereof.
[0037] Other suitable organic materials, either as the organic
matrix into which the inorganic particles are mixed, or as the
functional coatings on the inorganic particles, include polyvinyl
butyral (PVB) such those sold under the Butvar.RTM. trademark,
available from Solutia, St. Louis, Mo., or Liquid Nails.RTM.,
available from Akzo Nobel, Strongsville, Ohio.
[0038] Inorganic Seal Materials.
[0039] A variety of inorganic materials, usually particulate, are
suitable in the seal. For example, (a) mica (sheets or flakes), (b)
index matched glass powders (glass chemistry is not critical,
however Na--B--Si and B--Si glass are preferred) and (c)
hygroscopic inorganic additives such as zeolites, molecular sieves
and other desiccant materials, (d) metal powders or flakes (up to 5
microns). Metalized PET/Mylar with metals such as aluminum are also
suitable.
[0040] A variety of metals can be used, for example aluminum,
copper, nickel, iron, stainless steel, 102 stainless steel, 201
stainless steel, 202 stainless steel, 300 series stainless steel,
302 stainless steel, 304 stainless steel, 308 stainless steel, 309
stainless steel, 316 stainless steel, 321 stainless steel, 405
stainless steel, 408 stainless steel, 409 stainless steel, 410
stainless steel, 416 stainless steel, 420 stainless steel, 430
stainless steel, 439 stainless steel, 440 stainless steel, 446
stainless steel, 501 stainless steel, 502 stainless steel, 630
stainless steel, 2205 stainless steel, 2304 stainless steel, 2507
stainless steel, Ni--Fe alloys, Ni--Cr alloys, chromium,
molybdenum, tungsten, Invar, Kovar, Alloy 36, and Alloy 42, Alloy
42-6, Alloy 48, Alloy 49, Alloy 52, Alloy 600, Alloy 625, Inconel,
Alloy 718, Nickel 200, Nickel 201, Nickel 205, Nickel 233, Nickel
270, aluminum alloys such as AL1050, AL1060, AL1100, AL3003,
AL6063, AL5052, AL514, AL6061, AL384, AL2024, Tin, any of the
foregoing coated in a polymer, any of the foregoing coated in any
organic material disclosed elsewhere herein, and solders or alloys
of any two or more of the foregoing.
[0041] The inorganic seal material may be a plurality of inorganic
particles coated with any organic material disclosed herein. For
example, the inorganic particles may be any of metal, glass, metal
oxides, silica, quartz, cements, inorganic polymers, mica sheets,
mica flakes, glass powders, Na--B--Si glass, B--Si glass,
hygroscopic inorganic additives, zeolites, molecular sieves,
desiccant materials, calcium chloride, calcium sulfate, magnesium
chloride, zinc chloride, potassium carbonate, potassium phosphate,
carnallite, ferric ammonium citrate, potassium hydroxide, and
sodium hydroxide, metal powders up to 5 microns, metal flakes up to
5 microns.
[0042] In general the inorganic particle sizes (D.sub.50) can range
from 0.1 to 2000 microns, and possibly 5-1000 microns, 10-500
microns, 20-400 microns, 25-250 microns, 30-200 microns, or 0.5-80
microns, alternately 1-100 microns, 5-90 microns and 10-80 microns.
The longest dimension is typically defined to be length. Aspect
ratio is defined herein as length to thickness (longest to shortest
dimension of a flake). The desired aspect ratio is greater than
five, preferably greater than 10, more preferably greater than 20,
still more preferably greater than 50, even more preferably greater
than 100, and alternatively, 2-50, 2-100, 5-100 and 10-20. The
particles can have shapes such as high sphericity, low sphericity,
irregular, equant, ellipsoidal, tabular, cylindrical, flake,
whisker and wire geometries.
[0043] Seal Glasses:
[0044] Suitable seal glasses include those having a melting point
less than 600.degree. C., preferably less than 550.degree. C., more
preferably less than 500.degree. C., selected from the group
consisting of vanadate glasses, lead glasses, tin glasses,
phosphate glasses, borate glasses, bismuth glasses, telluride
glasses, thallate glasses and Sn--Zn--P glasses.
[0045] The hybrid organic-inorganic composite can be applied as
either a paste or a tape using standard deposition/application
procedures or as a preform such as gasket seal. That is a preform
of the seal can be made separately out of this hybrid
organic-inorganic matrix composite. Subsequently the preform can be
placed in place between the surfaces to be sealed to make the
seals. The glass flake loaded curable organic material can be
applied to at least one substrate by a procedure selected from the
group consisting of tape casting, doctor blading, layer by layer
application, screen printing, spraying, ink jet printing and
combinations thereof.
[0046] Metal object. The metal object can be a sheet, plate, foil,
wire or metal item having another shape. The metal object is used
for conducting heat to the seal material in order to heat it and
melt/flow the organic portion. The metal object may be aluminum,
copper, nickel, iron, stainless steel, 102 stainless steel, 201
stainless steel, 202 stainless steel, 300 series stainless steel,
302 stainless steel, 304 stainless steel, 308 stainless steel, 309
stainless steel, 316 stainless steel, 321 stainless steel, 405
stainless steel, 408 stainless steel, 409 stainless steel, 410
stainless steel, 416 stainless steel, 420 stainless steel, 430
stainless steel, 439 stainless steel, 440 stainless steel, 446
stainless steel, 501 stainless steel, 502 stainless steel, 2205
stainless steel, 2304 stainless steel, 2507 stainless steel, 630
stainless steel, Ni--Fe alloys, Ni--Cr alloys, chromium,
molybdenum, tungsten, Invar, Kovar, Alloy 36, and Alloy 42, Alloy
42-6, Alloy 48, Alloy 49, Alloy 52, Alloy 600, Alloy 625, Inconel,
Alloy 718, Nickel 200, Nickel 201, Nickel 205, Nickel 233, Nickel
270, aluminum alloys such as AL1050, AL1060, AL1100, AL3003,
AL6063, AL5052, AL514, AL6061, AL384, AL2024, Tin, and alloys of
any two or more of the foregoing.
[0047] Active Layer. An active layer is an electric or electronic
device that is protected by the substrates and the seals of the
invention. Suitable active layers include vacuum insulated glass,
solar cell contact, solar cell, solar cell module, organic PV
device, plasma display device, nanocrystal display, electrochromic
device, electrochromic material system, sensors, suspended particle
device, micro-blind, liquid crystal device, smart window,
switchable window, smart glass, eglass, quantum dot devices,
thermolelectric devices, batteries, LED, SED, FED, OLED, LCD, DLP,
FLD, IMOD, TDEL, QDLED, TMOS, TPD, LCL, LPD, OLET, and combinations
thereof.
[0048] Method.
[0049] An embodiment of the invention is a method of forming a seal
between two substrates. The method may result in a device including
a seal, the device formed by a method of locally heating a sealing
material comprising: (a) providing a metal object between at least
two substrates; (b) providing a seal material between the two
substrates and at least partially surrounding the metal object, and
(c) heating the metal object to heat the seal material to a
temperature of at least 125.degree. C., wherein the substrate
temperature remains at least 20.degree. C. below the temperature
attained in the seal, to flow the seal material between the
substrates. The device may be any active layer disclosed
herein.
[0050] In one embodiment, in FIG. 1, assembly 100 includes
substrates 110 and 120, which are used with metal frame 130. Metal
frame 130 is coated with powder coating layers 140 and 150. Metal
frame 130 matches the dimensions of substrates 110 and 120. Metal
frame 130 includes a cut out space 135. Layers 110, 140, 130, 150,
and 120 are pressed together and metal frame 130 is heated in order
to flow powder coating layers 140 and 150 to effect adhesion and
seal between metal frame 130 and substrates 110 and 120. A cavity
inside the now sealed substrates 110 and 120 with metal frame 130
now results and may house an active layer.
[0051] In another embodiment, in FIG. 2, assembly 200 includes
substrates 210 and 220, which are used with metal frame 230. Metal
frame 230 is coated with powder coating layers 240 and 250. Metal
frame 230 is larger than dimension of substrates 210 and 220, yet
includes cutout 235. Powder coating layers 240 and 240 are sized to
match the dimensions of substrates 210 and 220, accounting for
cutout 235. Layers 210, 240, 230, 250, and 220 are pressed together
and metal frame 230 is heated in order to flow powder coating
layers 240 and 250 to effect adhesion and create a seal between
metal frame 230 and substrates 210 and 220. A cavity inside the now
sealed substrates 210 and 220 with metal frame 230 (owing to cutout
235) now results and may house an active layer. The portions of
metal frame 230 that extend beyond substrates 210 and 220 may or
may not be removed later.
[0052] FIG. 3 is a depiction of the end result of the process
depicted in FIG. 1 where 310 and 320 are the two substrates and 330
is the seal of the invention.
[0053] FIG. 4 is an alternate embodiment where instead of a metal
plate, a wire 430 is used to effect heating between substrates 410
and 420. The portion of the wire extending beyond the cover of the
substrates may be later removed.
[0054] Preheating may be used to locally heat a portion of the
sealant material prior to the main heating. Similarly it is
envisioned that sealing materials can be applied to the same
substrate (top or bottom) and selectively sealed to the other plate
with or without preheating the firing the sealing materials.
Preheating may be undertaken with a laser or induction heating.
Preheating may be undertaken to a temperature of, for example,
175-225.degree. C. Details on induction heating may be found in PCT
patent application PCT/US2012/054709, which is hereby incorporated
by reference.
[0055] Details about aspects of the invention can be found in one
or more of the following United States patent applications, all of
which are incorporated herein by reference: Ser. Nos. 10/864,304;
10/988,208; 11/131,919; 11/145,538; 11/384,838; 11/774,632;
11/846,552; 12/097,823; 12/298,956; 12/573,209; 61/324,356;
61/328,258; 61/366,568; and 61/366,578.
[0056] The term "comprising" provides support for "consisting
essentially of" and "consisting of:" It is envisioned that an
individual numerical value for a parameter, temperature, weight,
percentage, etc., disclosed herein in any form, such as presented
in a table, provides support for the use of such value as the
endpoint of a range. A range may be bounded by two such values. In
a single embodiment, more than one glass composition can be used,
and compositions comprising amounts and ranges from different
columns among the tables are also envisioned.
[0057] Certain embodiments of the invention are envisioned where at
least some percentages, temperatures, times, and ranges of other
values are preceded by the modifier "about." All compositional
percentages are by weight and are given for a blend prior to
firing. Numerical ranges of oxides or other ingredients that are
bounded by zero on the lower end (for example, 0-10 mole % ZnO) are
intended to provide support for the concept "up to [the upper
limit]," for example "up to 10 mole % ZrO.sub.2" as well as a
positive recitation that the ingredient in question is present in
an amount that does not exceed the upper limit.
[0058] Each numerical range disclosed herein that is bounded by
zero, has, as an alternative embodiment, a lower bound of 0.1%
instead of zero. All ranges disclosed herein are to be understood
to encompass the beginning and ending range values and any and all
subranges therein. For example, a stated range of "1 to 10" should
be considered to include any and all subranges between (and
inclusive of) the minimum value of 1 and the maximum value of 10;
that is, all subranges beginning with a minimum value of 1 or more
and ending with a maximum value of 10 or less, e.g., 1.0 to 2.7,
3.3 to 8.9, 5.7 to 10, or individual values like 3.14159, 5.17,
8.07 or 9.58 for example. In other words, ranges are used as
shorthand for describing each and every value that is within the
range. Any value within the range can be selected as a terminus of
a subrange within the range.
* * * * *