The invention relates to a process for manufacturing complex parts comprising dyed embedded etched structures with micron-sized dimensions (i.e. microscale structures) and produced by joining elementary substrates by molecular bonding.
The invention therefore especially allows a part containing an embedded pattern to be manufactured, the dimensions of which are at most micron-sized.
The expression “dimensions are at most micron-sized” is understood to signify an embedded pattern the largest dimension of which is typically smaller than 1 mm, and preferably smaller than 500 μm or 250 μm.
The invention has applications in various industrial, cultural or artistic fields. It may thus be applied in the watch and clock making industry to produce very high-quality graphics or semitransparent decorations in watch glasses or on watch casings. In the field of jewelry, it may be used to produce gems comprising micron-sized or even nanoscale decorations or texts.
In the aforementioned fields of jewelry and gem cutting or watch and clock making, the use of micromechanical and micro-connection techniques and of electronic components is widespread. Microtechnology is thus in particular used to produce elementary components, for example a spiral spring made of silicon (especially used by Ulysse Nardin®).
In contrast, there are no known applications for complex parts made from permanently joined, optionally micro-machined, crystals or other substrates comprising microscopic etchings. A fortiori, there are no known applications for producing complex parts comprising micron-sized or even nanoscale dyed etchings within complex structures.
The production of microscopic etchings, for decorative purposes, graphics or texts is known. Several companies such as Graphilux International, Norsam or Lightsmith provide etchings produced on the surface of generally rather weak substrates; however, these etchings would not appear to be very durable and mechanically robust. By way of example, in document FR 2 851 496 of Jean-Louis Savoyet et al., it is proposed to securely fasten the object and its graphic by bonding, crimping or inclusion. These techniques have several limitations. Adhesives are organic materials possibly, on the one hand, having a limited lifetime, and on the other hand, optical properties that change over time and degrade the readability of the graphics. Crimping produces a solid mechanical assembly but does not provide enough robustness from the point of view of the integrity of the object and its graphic to, for example, ensure inviolable traceability. This is because crimping can be undone without destroying the object.
Moreover, technologies are known for producing extremely robust micron-sized images with excellent definition, which allow the aforementioned limitations to be avoided. In this respect, the following two documents may be cited.
Document FR 2 926 747 (CEA—invention of A. Rey and C. Deguet) relates to an object comprising a graphical element added to a medium and to a process for producing such an object; such an object is equipped with at least one graphical element comprising at least one layer etched with a graphical pattern element, a first side of said layer being placed facing one side of at least one partially transparent substrate, a second side of said layer, opposite the first side, being covered with at least one passivation layer securely fastened to at least one side of at least one medium by molecular bonding, and forming, with the medium, a monolithic structure. In practice, the etched layer is formed, before etching, by deposition on the substrate; after the etching has been carried out, this etched layer is coated with the passivation layer, which is also deposited.
Document FR 2 926 748 (CEA—invention by A. Rey, J. F. Clerc, A. Soubie) relates to an object equipped with a graphical element added to a medium and to the process for producing such an object. This object is equipped with at least one graphical element comprising at least one at least partially transparent substrate at least one side of which comprises hollows forming a graphical pattern element filled with at least one material, said side of the substrate being securely fastened to at least one side of at least one medium by molecular adhesion, the substrate and the medium forming a monolithic structure
It will be noted that, in these documents, the color of the graphical elements is set either by the material of the etched layer or by the filling material, which in practice leads to a choice that is limited to shades of grey, or yellow in the case of gold.
Moreover, there are many techniques for printing color images onto flexible or rigid media. However, at the present time known techniques do not allow very small permanent color images to be produced using micron-sized or even nanoscale pixels. Furthermore, these techniques do not allow images to be produced that resist mechanical attack (scratches), chemical attack, biological attack (mold), and thermal attack (fire).
In a different technical field, it is known to produce CMOS or CCD image sensors that use small colored pixels, however the latter are not intended to hold permanent images.
The object of the invention is to overcome the aforementioned drawbacks by providing a process for producing parts comprising embedded micron-sized or even nanoscale etchings, which can be dyed with a wide range of colors and shades, within structures that are joined as durably as possible.
The invention provides for this purpose a process for producing a part containing an embedded pattern the dimensions of which are at most micron-sized, in which:
Preferably, the process of the invention is applied to the production of complex transparent parts, advantageously formed from transparent crystals, which may be natural or synthetic crystals.
It will be understood that the process of the invention has many advantages, among which the following may be mentioned:
it allows complex parts to be produced from a large monolithic (for example crystal) substrate, which is difficult if not impossible to achieve with mechanical machining;
it also allows several types of substrate chosen for their physical (color etc.), chemical or mechanical properties to be joined; and
it provides the parts produced with unrivalled robustness, reliability, and durability.
According to advantageous features, which can optionally be combined:
It will be understood that it is advantageous, after the fluid dye has been injected, to block the communication passages between the hollow volume and exterior, especially if fluid dye remains in the hollow volume.
The invention also relates to a part obtained by such a process, i.e. a part containing an embedded pattern the dimensions of which are at most micron-sized, comprising first and second substrates at least one of which is transparent, and which are bonded to each other by molecular bonding, at least one hollow volume being formed in one and/or other of the substrates in immediate proximity to the bonding interface and opening onto the exterior, at least certain of the walls of this hollow volume being covered with a dying component; this dying component may consist of dying particles; this component may, as a variant, form part (or even consist of) a colored liquid at least partially filling this hollow volume.
The part (which may be a piece of jewelry or a timepiece) thus defined preferably has advantageous features resulting from those mentioned with regards to the process; among which, in particular, the following may be mentioned:
These parts may find applications in many fields:
luxury goods, in complex parts for timepieces or uncrimped gem assemblies for jewelry;
but also in decorations; and
even in ultra long-term data storage.
It will be noted that known processes do not involve forming trenches that are not filled with a solid material, having surface finishes controlled in order to provide optical or physical functions.
Objects, features and advantages of the invention will become clear from the following description, which is given by way of nonlimiting illustration and with regard to the appended drawings in which:
The figures schematically show the process of the invention, in which:
Thus,
This first substrate 11 is advantageously transparent and is either amorphous (glass etc.) or crystalline (sapphire, quartz, diamond etc.). It is advantageously a crystal.
First (see
Next (see
Next (see
The trenches may be structured as required:
In the example considered here, the other of the substrates, referenced 21 in
The melting point of the substrates 11 and 21 is above 25° C., and preferably above 200° C., 400° C. or 1000° C.
The configuration of the trenches formed in one and/or other of the substrates is chosen so that, conjointly, these trenches bound, after the subsequent bonding step, a hollow volume the configuration of which defines the embedded pattern to be produced.
After the etching mask has been removed, a surface treatment may be carried out (deposition of a layer providing a chemical functionalization, PVD or CVD deposition etc.), this surface treatment may also be selectively removed, for example by chemical-mechanical polishing of the top parts of the trenches, in order to remove traces of the etching step.
These micro-etched crystals may then be mechanically machined into the desired shapes (for example into a heart shape for a piece of jewelry)
The trenches defined in one and/or other of the substrates are such that the hollow volume communicates with the exterior (this will become clearer below), at least after the optional machining step used to define the outline of the future bonded assembly.
The various substrates or crystals, whether natural or synthetic, with microscopic etchings or unetched, are joined together by direct bonding, a.k.a molecular bonding, without an intermediate adhesive layer.
To do this, the substrates advantageously receive a specific surface treatment, known per se (modification of the roughness, planarity, cleaning, surface preparation (wet and/or dry activation); they are then brought into contact, with a precise alignment if necessary, especially if complementary trenches have been formed in each of the substrates. The direct bonding is strengthened by a heat treatment, for example at a temperature between 200 and 950° C. depending on the robustness desired and the materials used. The temperature of this heat treatment however remains below the melting point of the substrates 11, 21.
In
In the left-hand part of
It should be understood here that this communication with the exterior may also be achieved by way of another (or a plurality of other) hollow volume(s).
In the right-hand part, the second substrate comprises a trench 27 placed facing one (13B′) of the trenches 13A′ and 13B′, so as to form, conjointly, a hollow volume 26′ partially located in the first substrate 11′ and partially in the second substrate 21 (in the example considered, this trench 27 faces a portion protruding from this substrate, thereby placing left- and right-hand portions of the trench 13B′ in communication). Providing trenches in each of the substrates makes it possible to produce complex configurations. The difference in the depth of the trenches 13 A′ and 13 B′, on the one hand, and the trench 27, on the other hand, may allow, during the subsequent dying step, slightly different shades to be obtained using the same fluid dye. Trenches (not shown) form channels of communication with the exterior (not shown), these trenches being located along the bonding face.
The bonding interface of the left-hand part is referenced I and that of the right-hand part is referenced I′.
One or more cut crystals (see the octagon 30 in
With reference to
It will be understood that the interface between the substrates is all the harder to see the more the constituent materials of the two substrates have compositions and properties that are similar; this interface is substantially invisible in the case of substrates made from identical materials.
According to the invention, a step of dying the substrates is carried out after they are joined. The dying is obtained by injecting a colored fluid substance into at least some of the hollow volumes defined by the trenches, at the bonding interface. The colored fluid substance infiltrates by capillary action and thus allows the hollow volume in question to be dyed. For this purpose, infiltration pathways, existing between the etched parts and the bonded parts of the crystals, are used; with reference, by way of example, to the left-hand part of
The colored fluid substance may take the form of a liquid or gas. Multicolor dying may be obtained by defining different single-color infiltration pathways. Likewise, it is possible to promote variations in shade by mixing colors. It may be a fluid, for example a solvent, filled with dying particles that are advantageously deposited on the walls of the hollow volume.
It will be understood that the dynamic of the capillary infiltration depends on the dimensions of the infiltration pathways and of the hollow volumes, on the distance to be traveled by infiltration, and on the viscosity of the fluid substance; in the case of multiple hollow volumes there is a compromise to be found between the number of infiltration pathways and the number of hollow volumes connected in series (if all the hollow volumes are connected in series, the infiltration dynamic will be slow; if specific infiltration pathways are provided for each hollow volume, the dynamic will be more rapid but at the cost of the routing of the infiltration pathways possibly being complex). If required, this infiltration may be carried out at a temperature above room temperature in order to reduce viscosity.
Specifically, when the fluid dye is a gas, it would be expected that it would flow easily in the hollow volume. In contrast, when it is a liquid, it may be difficult to make it flow in the hollow volume. One way of promoting the injection and flow of the fluid, especially when it is a liquid, is to apply a heat treatment that acts to reduce the viscosity of the fluid, but also, if required, promotes evaporation of the constituent solvent of the fluid when it is a liquid.
When it is desired to trap the fluid dye in the hollow volume, the communication orifices are advantageously blocked after a sufficient amount of fluid has been injected (see below).
During the dying step (see
The dying results, either from the deposition of dying particles on the walls of the hollow volume, especially the walls (or sides) parallel to the bonding interface, but also its sidewalls, or from the presence of the colored fluid itself in the hollow volume. It will be understood, in the case of particle deposition, that the effect of trapping of the dying particles on these walls depends on their surface finish, and that it may be advantageous for the surfaces of these walls not to be too smooth. It will also be understood, when the dying mainly results from the presence of fluid trapped in the hollow volume, that the flow of this fluid may be extremely limited (for example just enough to allow total or partial filling of the hollow volume). Of course, both a substantial flow of fluid and the presence of a trapped fluid may lead to dying particles being deposited on the walls (sidewalls or otherwise).
It will be understood that the shorter the inlet/outlet pathways are, the smaller the risk that regions other than those desired will be dyed; however, this risk may be minimized by making the walls of these pathways very smooth.
In particular, solutions colored with nano particles in solution may in particular be used. These nano particles may be very small sized metal particles, for example gold (Au) particles about a few nanometers in size and possibly ranging up to about 100 nm in size. These particles may be protected by a carapace that provides them with a good thermal resistance, for example a zirconia (ZrO2) carapace around gold particles. This carapace modifies the optical properties of the particle, and this must be taken into account when considering how to implement the process. The choice of materials and size of the nanoparticles will be made depending on the color properties desired.
By modifying the size and density of the particles (for example the gold particles described above), different colors (yellow, red, green, etc.) and shades of color can be obtained, via diffraction effects, as required.
Other dying particles may be used. Thus, the particles may especially be mineral particles, and, for example, comprise an oxide such as iron oxide, chromium oxide, manganese oxide, or aluminum oxide, or mixtures of such oxides, or comprise a metal or an alloy such as spinel, chromium or cobalt.
The particles may also be organic particles, phthalocyanine particles for example.
The particles may also be Au, Ag or Pt plasmonic particles or even using particles made of organic molecules in a mineral matrix.
As a variant, the particles may be coated with refractory materials such as alumina, zirconia, or zircon.
The particles may be suspended in a solvent; when the dying is intended to be achieved by trapping the fluid in the hollow volume, the color is advantageously stable throughout the volume of this fluid.
The assemblies obtained in this way after this dying step may be a wide range of sizes, even if the relative proportions between the outline of this assembly and the dimensions of the hollow volume are in fact very different from those shown in figures.
These assemblies, which make up the parts that it is desired to produce, may be subjected, especially if it is desired to keep the injected colored fluid therein, to a coating operation for hermetically sealing (for example using resins or a polymer or an adhesive or even by local melting of the material (the expression “exhaust sealing” sometimes being used when the sealing takes place after gas contained in the hollow volume has been evacuated)) the interior of the hollow volumes by plugging the inlet/outlet infiltration pathways.
Thus, it will be appreciated that the present invention makes it possible to produce:
The invention may be applied in various industrial, cultural or artistic fields.
In the watch and clock making industry, complex watch parts (for example casings or mechanical subassemblies) can be produced by joining, by molecular bonding, machined or micro-machined crystals. This may especially be applied to what are called “skeleton” watches.
In the field of jewelry, gems, with or without decorations or text produced by etching on the microscale (even nanoscale), may be joined, without adhesive bonding or crimping, to metals. These parts may have complex shapes, and particularly allow the transparency or maximum optical effects of the component crystals to be emphasized by virtue of the absence of opaque metal parts.
However, various variants may be envisioned regarding the particular embodiments defined above. Thus, in particular, only one of the substrates may be transparent. The trenches may be obtained by depositing material around regions intended to form the hollow volumes. The chambers may be separated by continuous partitions.
Number | Date | Country | Kind |
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1059214 | Nov 2010 | FR | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP11/68819 | 10/27/2011 | WO | 00 | 6/7/2013 |