Methods and apparatus for forming shaped articles, shaped articles, methods for manufacturing liquid lenses, and liquid lenses

Patent metadata

Field	Value
Publication number	US-11577992-B2
Application number	US-201816754655-A
Country	US
Kind code	B2
Filing date	Oct 12, 2018
Priority date	Oct 13, 2017
Publication date	Feb 14, 2023
Grant date	Feb 14, 2023

Abstract

A method includes depositing a surface modification layer on sidewalls of a plurality of cavities of a shaped article. The surface modification layer is formed from a glass material including a mobile component. The shaped article is formed from a glass material, a glass ceramic material, or a combination thereof. At least a portion of the mobile component is migrated from the surface modification layer into surface regions of the sidewalls of the shaped article, whereby subsequent to the migration, the surface regions have a reduced annealing point compared to a bulk of the shaped article. The surface modification layer and the surface regions of the sidewalls are reflowed. A surface roughness of the surface modification layer disposed on the sidewalls following the reflowing is less than a surface roughness of the sidewalls prior to the depositing.

First claim

What is claimed is:

1. A shaped article comprising:
a plate comprising a glass material, a glass-ceramic material, or a combination thereof;
a plurality of cavities formed in the plate; and
a surface modification layer disposed on sidewalls of the plurality of cavities, the surface modification layer comprising a glass material comprising a mobile component;
wherein doped regions of the plurality of cavities adjacent the surface modification layer comprise a gradient in a concentration of the mobile component.

2. The shaped article of claim 1 , wherein the surface modification layer disposed on the sidewalls has a thickness of at least about 1000 nm.

3. The shaped article of claim 1 , wherein a concentration of the mobile component in the glass material of the surface modification layer is at least about 10 wt %.

4. The shaped article of claim 1 , wherein a surface roughness of the surface modification layer disposed on the sidewalls is at most about 500 nm.

5. The shaped article of claim 1 , wherein the glass material of the surface modification layer comprises a fluorosilicate glass, and the mobile component comprises fluorine.

6. The shaped article of claim 1 , wherein the glass material of the surface modification layer comprises a borosilicate glass, and the mobile component comprises boron.

7. The shaped article of claim 1 , wherein the glass material, the glass-ceramic material, or the combination thereof of the shaped article comprises a silicate glass, a silicate glass-ceramic, or a combination thereof.

8. The shaped article of claim 1 , wherein the gradient in the concentration of the mobile component is a result of migration of at least a portion of the mobile component from the surface modification layer into surface regions of the sidewalls of the shaped article to form the doped regions.

9. The shaped article of claim 1 , wherein a softening point of the glass material of the surface modification layer is less than a softening point of the glass material, the glass-ceramic material, or the combination thereof of the shaped plate.

10. The shaped article of claim 1 , wherein:
the surface modification layer disposed on the sidewalls of the plurality of cavities defines coated sidewalls of the plurality of cavities;
each of the plurality of cavities has a truncated conical shape; and
the coated sidewall of each of the plurality of cavities is substantially straight.

11. A method comprising:
depositing a surface modification layer on sidewalls of a plurality of cavities of a shaped article, the surface modification layer comprising a glass material comprising a mobile component, the shaped article comprising a glass material, a glass-ceramic material, or a combination thereof;
migrating at least a portion of the mobile component from the surface modification layer into surface regions of the sidewalls of the shaped article, whereby subsequent to the migration, the surface regions have a reduced annealing point compared to a bulk of the shaped article; and
reflowing the surface modification layer and the surface regions of the sidewalls;
wherein a surface roughness of the surface modification layer disposed on the sidewalls following the reflowing is less than a surface roughness of the sidewalls prior to the depositing.

12. The method of claim 11 , wherein the glass material of the surface modification layer comprises a fluorosilicate glass, and the mobile component comprises fluorine.

13. The method of claim 11 , wherein the glass material of the surface modification layer comprises a borosilicate glass, and the mobile component comprises boron.

14. The method of claim 11 , wherein the glass material, the glass-ceramic material, or the combination thereof of the shaped article comprises a silicate glass, a silicate glass-ceramic, or a combination thereof.

15. The method of claim 11 , wherein the depositing comprises depositing the surface modification layer on the sidewalls using chemical vapor deposition.

16. The method of claim 11 , comprising heating the surface modification layer to a heating temperature for a heating time sufficient to cause the migrating and the reflowing.

17. The method of claim 16 , wherein the heating temperature is less than a softening point of the bulk of the shaped article.

18. A liquid lens comprising:
a lens body comprising a first window, a second window, a cavity disposed between the first window and the second window, and a surface modification layer disposed on a sidewall of the cavity, the lens body comprising a glass material, a glass-ceramic material, or a combination thereof, the surface modification layer comprising a glass material comprising a mobile component, a doped region of the cavity adjacent the surface modification layer comprising a gradient in a concentration of the mobile component; and
a first liquid and a second liquid disposed within the cavity of the lens body, the first liquid and the second liquid substantially immiscible with each other and having different refractive indices such that an interface between the first liquid and the second liquid forms a lens.

19. The liquid lens of claim 18 , wherein:
the glass material of the surface modification layer comprises a fluorosilicate glass, a borosilicate glass, or a combination thereof; and
the mobile component comprises fluorine, boron, or a combination thereof, respectively.

20. The liquid lens of claim 18 , wherein the glass material, the glass-ceramic material, or the combination thereof of the shaped article comprises a silicate glass, a silicate glass-ceramic, or a combination thereof.

Assignees

• Corning Inc

Inventors

• Bellman Robert Alan
• Dawson-Elli David Francis
• Liu Shiwen
• Wang Chuanche

Classifications

• G02B3/12 Primary

  Fluid-filled or evacuated lenses · CPC title

• C03C23/007

  by thermal treatment · CPC title

• C03C17/02 Primary

  with glass (C03C17/34, C03C17/44 take precedence) · CPC title

• C03C2217/77

  Coatings having a rough surface · CPC title

• B29D11/00375

  by moulding lenses in holes through a substrate · CPC title