Seals for optical components

Patent metadata

Field	Value
Publication number	US-12157289-B2
Application number	US-202318457522-A
Country	US
Kind code	B2
Filing date	Aug 29, 2023
Priority date	Sep 16, 2022
Publication date	Dec 3, 2024
Grant date	Dec 3, 2024

Abstract

An electronic device may have optical components that each have first and second transparent layers such as first and second glass layers. The glass layers may have outer surfaces that face away from each other and inner surfaces that face towards each other. A polymer layer is formed between the inner surfaces of the glass layers. Along the periphery of each optical component, a hermetic seal is formed to protect the polymer material of the polymer layer. The seal may include one or more metal layers that are coupled to the first and second glass layers. For example, glass prism rings may be coupled to the first and second glass layers and metal may be coupled to the prism rings. The one or more metal layers may then be bonded to the metal on the prism rings, such as through soldering.

First claim

What is claimed is:

1. An optical component, comprising:
first and second transparent layers;
a polymer layer between the first and second transparent layers, wherein the polymer layer has a peripheral edge;
first and second metal layers respectively adjacent to the first and second transparent layers; and
a seal formed from a barrier layer that hermetically seals the peripheral edge, wherein the barrier layer is coupled to the first and second metal layers.

2. The optical component of claim 1 , wherein the barrier layer comprises first and second L-shaped metal layers.

3. The optical component of claim 2 , wherein the first and second L-shaped metal layers comprise plated aluminum.

4. The optical component of claim 2 , wherein the first and second L-shaped metal layers have overlapping portions that overlap the peripheral edge, and wherein the overlapping portions are soldered.

5. The optical component of claim 1 , wherein the first and second transparent layers are glass, the optical component further comprising:
first and second glass prism rings respectively coupled to the first and second transparent layers.

6. The optical component of claim 5 , wherein the first and second glass prism rings comprise first surfaces that are welded to the first and second transparent layers, the first and second glass prism rings comprise second surfaces, and the first and second metal layers are respectively formed on the second surfaces of the first and second glass prism rings.

7. The optical component of claim 6 , wherein the barrier layer is soldered to the first and second metal layers.

8. The optical component of claim 6 , further comprising:
first and second portions of desiccant material respectively interposed between the first and second glass prism rings and the barrier layer.

9. The optical component of claim 1 , further comprising:
a buffer layer interposed between the peripheral edge and the barrier layer.

10. The optical component of claim 9 , wherein the buffer layer comprises a metal foil layer, and wherein the metal foil layer is plated with nickel and gold.

11. The optical component of claim 1 , further comprising:
a first layer of dark deposition material interposed between the first transparent layer and the first metal layer; and
a second layer of dark deposition material interposed between the second transparent layer and the second metal layer.

12. The optical component of claim 11 , wherein the first and second layers of dark deposition material comprise a material selected from the group consisting of: amorphous silicon, chromium, CrC, Tungsten, WC, and nickel.

13. The optical component of claim 11 , wherein the first and second metal layers each comprises a first metal layer, a second metal layer, and a third metal layer, wherein the first metal layer is in contact with the first layer of dark deposition material or the second layer of the dark deposition material, the optical component further comprising:
solder between the barrier layer and the third metal layers.

14. The optical component of claim 13 , wherein the first metal layer comprises titanium or chromium, the second metal layer comprises nickel or copper, and the third metal layer comprises silver or gold.

15. An optical component, comprising:
a first glass layer comprising first and second opposing surfaces;
a second glass layer comprising third and fourth opposing surfaces;
a polymer layer coupled to the second and third surfaces;
a first glass prism ring coupled to the first surface;
a second glass prism ring coupled to the fourth surface; and
a seal formed along a peripheral edge of the polymer layer, wherein the seal includes a barrier layer that is coupled to the first glass prism ring and to the second glass prism ring.

16. The optical component of claim 15 , further comprising:
first and second metal layers respectively formed on the first and second glass prism rings, wherein the barrier layer is soldered to the first and second metal layers.

17. The optical component of claim 16 , wherein the barrier layer comprises first and second L-shaped metal layers, the first L-shaped metal layer is soldered to the first metal layer, the second L-shaped metal layer is soldered to the second metal layer, and the first and second L-shaped metal layers are soldered together.

18. The optical component of claim 17 , wherein the first and second glass prism rings are welded to the first and fourth surfaces.

19. The optical component of claim 18 , wherein the first and second glass prism rings are triangular prism rings having first, second, and third sides, wherein the first and second metal layers are sputtered onto the first sides of the first and second glass prism rings, and wherein the second sides are welded to the first and fourth surfaces.

20. The optical component of claim 19 , wherein the third sides of the first and second glass prism rings form laser-welding windows.

21. The optical component of claim 17 , wherein the first and second L-shaped metal layers comprise nickel-and-gold-plated metal foils.

22. The optical component of claim 17 , wherein the first and second L-shaped metal layers have thicknesses of less than 30 microns.

23. An electronic device, comprising:
a support structure;
an optical component supported by the support structure, wherein the optical component has first and second glass layers, and has a polymer layer between the first and second glass layers; and
a hermetic seal formed along a peripheral edge of the optical component, wherein the hermetic seal comprises:
first and second glass prism layers respectively formed on the first and second glass layers;
third and fourth metal layers respectively formed on the first and second glass prism layers;
a first metal layer soldered to the third metal layer; and
a second metal layer soldered to the fourth metal layer.

24. The electronic device of claim 23 , wherein the first and second metal layers are soldered together, and wherein the first and second glass prism layers are respectively welded to the first and second glass layers.

25. An optical component, comprising:
first and second transparent layers;
a polymer layer between the first and second transparent layers, wherein the polymer layer has a peripheral edge;
desiccant tape adjacent to the first and second transparent layers; and
a seal formed from a barrier layer that hermetically seals the peripheral edge, wherein the barrier layer is coupled to the first and second transparent layers with the desiccant tape.

26. The optical component of claim 25 , wherein the barrier layer comprises first and second metal layers that are respectively soldered to the first and second transparent layers.

27. The optical component of claim 26 , wherein the barrier layer further comprises primer between the first and second metal layers and the first and second transparent layers.

28. The optical component of claim 27 , wherein the first and second metal layers comprise copper foil layers.

29. The optical component of claim 25 , wherein the barrier layer comprises a single soft metal foil layer.

30. The optical component of claim 25 , wherein the barrier layer comprises first and second metal layers that are respectively attached to the first and second transparent layers with only the d

Assignees

• Apple Inc

Inventors

• Lin Wei
• Fu Boyi
• Gupta Nathan K

Classifications

• B32B17/1022 Primary

  Metallic coatings · CPC title

• B32B2551/00

  Optical elements · CPC title

• B32B17/1077

  containing polyurethane · CPC title

• B32B2457/00

  Electrical equipment · CPC title

• B32B17/10036

  comprising two outer glass sheets · CPC title