PATENT DOCUMENT

Publication Number: US-10781135-B2
Application Number: US-201113235036-A
Country: US
Kind Code: B2

Title: Strengthening variable thickness glass

Abstract:
Apparatus, systems and methods for increasing the strength of glass are disclosed. The use of multi-bath chemical processing for a glass article can facilitate controlled chemical strengthening. Through multi-bath (or multi-step) chemical processing, differing levels of strengthening can be achieved for different portion of glass articles. The multi-bath chemical processing can be achieved through the use of successive chemical baths. Accordingly, glass articles that have undergone multi-bath chemical processing are able to be not only thin but also sufficiently strong and resistant to damage. The strengthened glass articles are well suited for use in consumer products, such as consumer electronic devices (e.g., portable electronic devices). In one embodiment, the glass member can pertain to a glass cover for a housing of an electronic device.

Claims:
What is claimed is: 
     
       1. A method for chemically strengthening a piece of glass for use as a cover for an electronic device, the method comprising:
 providing a piece of glass, the piece of glass having:
 a first portion defining a middle region of a substantially planar top surface of the piece of glass and having a first thickness that is between 0.2 mm and 0.4 mm thick; and 
 a second portion defining a side region along a periphery of the substantially planar top surface of the piece of glass and having a second thickness that is between 0.6 mm and 1.0 mm thick; 
 
 applying a mask to the first portion of the piece of glass; 
 chemically strengthening the second portion of the piece of glass by placing the piece of glass in a first bath; 
 subsequently removing the mask from the first portion of the piece of glass; 
 chemically strengthening the first portion and the second portion of the piece of glass by placing the piece of glass in a second bath, such that:
 the chemically strengthened first portion has a first depth of layer of between 30 microns and 40 microns; and 
 the chemically strengthened second portion has a second depth of layer of between 50 microns and 60 microns; and 
 
 positioning the piece of glass over a display of an electronic device. 
 
     
     
       2. A method as recited in  claim 1 , wherein the chemically strengthening of the first portion to the first depth of layer of between 30 microns and 40 microns provides a first predetermined characteristic to the first portion. 
     
     
       3. A method as recited in  claim 2 , wherein the chemically strengthening of the second portion to the second depth of layer of between 50 microns and 60 microns provides a second predetermined characteristic to the second portion. 
     
     
       4. A method as recited in  claim 3 , wherein:
 the first predetermined characteristic pertains to a first central tension limit; and 
 the second predetermined characteristic pertains to a second-central tension limit. 
 
     
     
       5. A method as recited in  claim 1 , wherein the piece of glass has a thickness of not more than about 0.6 mm. 
     
     
       6. A method as recited in  claim 1 , wherein the first thickness is between about 20-70% of the second thickness. 
     
     
       7. A method for strengthening a piece of glass, the piece of glass comprising:
 a first portion defining a middle region of a substantially planar first surface and having a first thickness that is between 0.2 mm and 0.4 mm thick, and 
 a second portion defining a side region of the substantially planar first surface and having a second thickness that is between 0.6 mm and 1.0 mm thick, the side region extending around a periphery of the middle region, the method comprising: 
 applying a first mask to the second portion of the piece of glass; 
 chemically strengthening the first portion to a first depth of layer of between 30 microns and 40 microns; 
 subsequently removing the first mask from the second portion; 
 applying a second mask to the first portion; 
 chemically strengthening the second portion to a second depth of layer of between 50 microns and 60 microns; 
 subsequently removing the second mask from the first portion; and 
 attaching the piece of glass to a portable electronic device to define an outer surface of the portable electronic device. 
 
     
     
       8. A method as recited in  claim 7 , wherein the first thickness of the piece of glass is not more than about 0.6 mm. 
     
     
       9. A method as recited in  claim 8 , wherein the chemically strengthening of the first portion comprises placing the piece of glass in a first potassium solution. 
     
     
       10. A method as recited in  claim 9 , wherein the chemically strengthening of the second portion comprises placing the piece of glass in the first potassium solution or a second potassium solution. 
     
     
       11. A method as recited in  claim 7 , wherein the first thickness is 20-70% of the second thickness. 
     
     
       12. A method for strengthening a piece of glass for a housing for a portable electronic device defining a substantially planar surface and having a thinner region and a thicker region, the method comprising:
 applying a first mask to the thinner region of the piece of glass; 
 chemically strengthening the thicker region; 
 subsequently removing the first mask from the thinner region; and 
 chemically strengthening both the thinner region and the thicker region, such that;
 the chemically strengthened thinner region has a first depth of layer of between 30 microns and 40 microns; and 
 the chemically strengthened thicker region has a second depth of layer of between 50 microns and 60 microns, 
 
 wherein the thinner region corresponds to a middle region of the substantially planar surface having a first thickness that is between 0.2 and 0.4 mm thick, and the thicker region corresponds to a side region of the substantially planar surface surrounding the thinner region and having a second thickness that is between 0.6 to 1.0 mm thick; and 
 attaching the piece of glass to the portable electronic device. 
 
     
     
       13. A method as recited in  claim 12 , wherein the second thickness of the thicker region is not more than about 0.6 mm. 
     
     
       14. A method as recited in  claim 12 , wherein:
 the chemically strengthening of the thicker region comprises placing the piece of glass in a first potassium solution, and 
 the chemically strengthening of the thinner region comprises placing the piece of glass in the first potassium solution or a second potassium solution. 
 
     
     
       15. A method for processing a glass piece for use as a cover for an electronic device, the method comprising:
 masking a first portion of the glass piece to block ion exchange; 
 submerging the glass piece in a heated ion bath to facilitate ion exchange with at least a second portion of the glass piece other than the first portion which is masked; 
 removing the glass piece from the heated ion bath after a first predetermined duration; 
 unmasking the first portion of the glass piece after removing the glass piece from the heated ion bath; 
 subsequently submerging the glass piece in the heated ion bath or another heated ion bath to facilitate ion exchange with at least the first portion of the glass piece; and 
 removing the glass piece from the heated ion bath or the another heated ion bath after a second predetermined duration; and 
 positioning the glass piece over a display of an electronic device, 
 wherein the glass piece defines a substantially planar surface having a middle region and an outer peripheral region, the first portion defines at least part of the middle region of the substantially planar surface and has a first thickness that is between 0.2 and 0.4 mm thick, the first portion has a first depth of layer of between 30 microns and 40 microns, the second portion defines at least part of the outer peripheral region of the substantially planar surface and has a second thickness that is between 0.6 to 1.0 mm thick, and the second portion has a second depth of layer of between 50 microns and 60 microns. 
 
     
     
       16. A method as recited in  claim 15 , wherein the method further comprises:
 performing post-processing on the glass piece following removal of the glass piece from the heated ion bath or the another heated ion bath. 
 
     
     
       17. A method as recited in  claim 15 , wherein
 positioning the glass piece comprises attaching the glass piece to a portable electronic device, the glass piece serving as a portion of an outer surface of a housing of the portable electronic device. 
 
     
     
       18. A method as recited in  claim 15 , wherein the glass piece has a thickness of not more than about 0.6 mm. 
     
     
       19. A consumer electronic product, comprising:
 a housing having a front surface, a back surface and side surfaces; 
 electrical components provided at least partially internal to the housing, the electrical components including at least a controller, a memory, and a display, the display being provided at or adjacent the front surface of the housing; and 
 a cover glass provided at or over the front surface of the housing such that it is provided over the display, the cover glass comprising:
 a middle region defining a first substantially planar surface and having a first thickness between 0.2 and 0.4 mm and a first level of chemical strengthening that has a first depth of layer of between 30 microns and 40 microns; and 
 a side region along a periphery of the cover glass, defining a second substantially planar surface that is substantially coplanar with the first substantially planar surface and having a second thickness between 0.6 to 1.0 mm and a second level of chemical strengthening that has a second depth of layer of between 50 microns and 60 microns. 
 
 
     
     
       20. A consumer electronic product as recited in  claim 19 , wherein the middle region is chemically strengthened to a lesser depth than the side region.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority benefit of U.S. Provisional Application No. 61/453,398, filed Mar. 16, 2011, and entitled “STRENGTHENING VARIABLE THICKNESS GLASS,” which is hereby incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     Conventionally, some portable electronic devices use glass as a part of their devices, either internal or external. Externally, a glass part can be provided as part of a housing, such a glass part is often referred to as a cover glass. The transparent and scratch-resistance characteristics of glass make it well suited for such applications. Internally, glass parts can be provided to support display technology. More particularly, for supporting a display, a portable electronic device can provide a display technology layer beneath an outer cover glass. A sensing arrangement can also be provided with or adjacent the display technology layer. By way of example, the display technology layer may include or pertain to a Liquid Crystal Display (LCD) that includes a Liquid Crystal Module (LCM). The LCM generally includes an upper glass sheet and a lower glass sheet that sandwich a liquid crystal layer therebetween. The sensing arrangement may be a touch sensing arrangement such as those used to create a touch screen. For example, a capacitive sensing touch screen can include substantially transparent sensing points or nodes dispersed about a sheet of glass. 
     Unfortunately, however, use of glass with portable electronic devices requires that the glass be relatively thin. Generally speaking, the thinner the glass the more susceptible the glass is to damage when the portable electronic device is stressed or placed under a significant force. Chemically strengthening has been used to strengthen glass. While chemically strengthening is effective, there is a continuing need to provide improved ways to strengthen glass, namely, thin glass. 
     SUMMARY 
     The invention relates generally to increasing the strength of glass. The use of multi-bath chemical processing for a glass article can facilitate controlled chemical strengthening. Through multi-bath (or multi-step) chemical processing, differing levels of strengthening can be achieved for different portion of glass articles. The multi-bath chemical processing can be achieved through the use of successive chemical baths. Accordingly, glass articles that have undergone multi-bath chemical processing are able to be not only thin but also sufficiently strong and resistant to damage. The strengthened glass articles are well suited for use in consumer products, such as consumer electronic devices (e.g., portable electronic devices). 
     The invention can be implemented in numerous ways, including as a method, system, device, or apparatus. Several embodiments of the invention are discussed below. 
     As a method for chemically strengthening a piece of glass, one embodiment can, for example, include at least: providing a piece of glass, the piece of glass having a first portion and a second portion, the first portion having a first thickness, the second portion having a second thickness, the second thickness being different than the first thickness; chemically strengthening the first portion to a first level; and chemically strengthening the second portion to a second level, the second level being different than the first level. 
     As a method for strengthening a piece of glass, the piece of glass having a first region with a first thickness and a second region with a second thickness, one embodiment can, for example, include at least: applying a first mask to the second region of the piece of glass; chemically strengthening the first region; subsequently removing the first mask from the second region; applying a second mask to the first region; chemically strengthening the second region; and subsequently removing the second mask from the first region. 
     As a method for strengthening a piece of glass, the piece of glass having a thinner region and a thicker region, another embodiment can, for example, include at least: applying a first mask to the thinner region of the piece of glass; chemically strengthening the thicker region; subsequently removing the first mask from the thinner region; and chemically strengthening both the thinner region and the thicker region. 
     As a method for processing a glass piece to improve its strength, one embodiment can, for example, include at least: masking a first portion of the glass piece to block ion exchange; submerging the glass piece in a heated ion bath to facilitate ion exchange with at least a portion of the glass piece other than the first portion which is masked; removing the glass piece from the heated ion bath after a first predetermined duration; unmasking the first portion of the glass piece after removing the glass piece from the heated ion bath; subsequently submerging the glass piece in the heated ion bath or another heated ion bath to facilitate ion exchange with at least the first portion of the glass piece; and removing the glass piece from the heated ion bath or the another heated ion bath after a second predetermined duration. 
     As a consumer electronic product, one embodiment can, for example, include at least a housing having a front surface, a back surface and side surfaces. At least partially internal to the housing, are electrical components. The electrical components can include at least a controller, a memory, and a display. The display can be provided at or adjacent the front surface of the housing. A cover glass can be provided at or over the front surface of the housing such that it is provided over the display. The cover glass can have a varied thickness at a plurality of different portions, and the plurality of different portions can be strengthened chemically strengthening differently. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  illustrates a glass strengthening system according to one embodiment. 
         FIG. 2  illustrates a glass article according to one embodiment. 
         FIG. 3  illustrates a glass article according to another embodiment. 
         FIG. 4  is a cross-sectional diagram of a glass article according to still another embodiment. 
         FIG. 5  is a flow diagram of a glass strengthening process according to one embodiment. 
         FIGS. 6A-6F  illustrate processing to chemically strengthened a glass article. 
         FIG. 7  is a flow diagram of a glass strengthening process according to another embodiment. 
         FIGS. 8A-8E  illustrate processing to chemically strengthened a glass article. 
         FIG. 9A  is a cross-sectional diagram of a glass cover which has been chemically treated such that a chemically strengthened layer is created according to one embodiment. 
         FIG. 9B  is a cross-sectional diagram of a glass cover which has been chemically treated, as shown to include a chemically treated portion in which potassium ions have been implanted according to one embodiment. 
         FIG. 10  is a diagrammatic representation of a chemical treatment process that involves submerging a glass cover in an ion bath according to one embodiment. 
         FIGS. 11A and 11B  are diagrammatic representations of electronic device according to one embodiment. 
         FIGS. 12A and 12B  are diagrammatic representations of electronic device according to another embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The invention relates generally to increasing the strength of glass. The use of multi-bath chemical processing for a glass article can facilitate controlled chemical strengthening. Through multi-bath (or multi-step) chemical processing, differing levels of strengthening can be achieved for different portion of glass articles. The multi-bath chemical processing can be achieved through the use of successive chemical baths. Accordingly, glass articles that have undergone multi-bath chemical processing are able to be not only thin but also sufficiently strong and resistant to damage. The strengthened glass articles are well suited for use in consumer products, such as consumer electronic devices (e.g., portable electronic devices). 
     Embodiments of the invention can relate to apparatus, systems and methods for improving strength of a thin glass member for a consumer product, such as a consumer electronic device. In one embodiment, the glass member may be an outer surface of a consumer electronic device. For example, the glass member may, for example, correspond to a glass cover that helps form part of a display area of the electronic device (i.e., situated in front of a display either as a separate part or integrated within the display). As another example, the glass member may form a part of a housing for the consumer electronic device (e.g., may form an outer surface other than in the display area). In another embodiment, the glass member may be an inner component of a consumer electronic device. For example, the glass member can be a component glass piece of a LCD display provided internal to the housing of the consumer electronic device. 
     The apparatus, systems and methods for improving strength of thin glass are especially suitable for glass covers or displays (e.g., LCD displays), particularly those assembled in small form factor electronic devices such as handheld electronic devices (e.g., mobile phones, media players, personal digital assistants, remote controls, etc.). The glass can be thin in these small form factor embodiments, such as less than 3 mm, or more particularly between 0.3 and 2.5 mm. The apparatus, systems and methods can also be used for glass covers or displays for other devices including, but not limited to including, relatively larger form factor electronic devices (e.g., portable computers, tablet computers, displays, monitors, televisions, etc.). The glass can also be thin in these larger form factor embodiments, such as less than 5 mm, or more particularly between 0.3 and 3 mm. 
     Embodiments of the invention are discussed below with reference to  FIGS. 1-12B . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. The illustrations provided in these figures are not necessarily drawn to scale; instead, the illustrations are presented in a manner to facilitate presentation. 
       FIG. 1  illustrates a glass strengthening system  100  according to one embodiment. The glass strengthening system  100  receives a glass article  102  to be strengthened through chemical processing. The glass article  102  is provided to a first bath station in which a first bath  104  is provided. The glass article  102  can be inserted (e.g., immersed) into the first bath  104  which includes a potassium solution  106 . Next, the glass article  102  is removed from the first bath station and provided to a second bath station. The second bath station provides a second bath  108 . The glass article can be inserted (e.g., immersed) into the second bath  108  which includes a potassium solution  110 . Later, the glass article  102  is removed from the second bath  108 . At this point, the glass article has been first enhanced and then strengthened. Through use of the multiple stages of chemical strengthening as well as masking portions of the glass article  102 , the chemical strengthening can be controllably induced into the glass article  102 . 
     Furthermore, following removal of the glass article from the second bath  108 , post-processing can be performed on the glass article  102 . Post-processing can vary widely dependent on intended application for the glass article. However, post-processing can, for example, include one or more of rinsing, polishing, annealing and the like. 
     The potassium solution  106  within the first bath  104  can be heated to a predetermined temperature, and the glass article  102  can be immersed within the first bath  104  for a predetermined period of time (duration). The degree of chemical strengthening of the glass article  102  is dependent on: (1) type of glass, (2) concentration of bath (e.g., K concentration), (3) time in the first bath  104 , and (4) temperature of the first bath  104 . Likewise, the potassium solution  110  within the second bath  108  can heated to a predetermined temperature, and the glass article  102  can be immersed within the second bath  108  for a predetermined period of time. The degree of chemically strengthening provided by the second bath  108  to the glass article is similarly dependent on: (1) type of glass, (2) concentration of bath (e.g., K concentration), (3) time in the second bath  108 , and (4) temperature of the second bath  108 . 
     In one implementation, the glass for the glass article  102  can, for example, be alumina silicate glass, soda lime glass or Lithium-based glass. Also, glass from different suppliers, even if the same type of glass, can have different properties and thus may require different values. In one embodiment the first bath  104  and the second bath  108  can be potassium nitrate (KNO3) baths. The time for the glass article  102  to remain immersed in the first bath  104  can, for example, be about 2-20 hours and the temperature for the first bath  104  can be about 350-450 degrees Celsius. The time for the glass article  102  to remain immersed in the second bath  108  can, for example, be about 2-20 hours and the temperature for the second bath  108  can be about 350-450 degrees Celsius. Also, an electronic field can be induced to assist with the chemical strengthening process, which would lower the duration of time the glass article  103  is to be immersed in an ion exchange bath and/or facilitate enhanced chemical strengthening. 
       FIG. 2  illustrates a glass article  200  according to one embodiment. The glass article  200  has a uniform thickness (t). Typically, the thickness for the glass article  200  depends on its usage. As an example, if the glass article  200  is destined for use as part of a portable electronic device, the thickness tends to be rather thin, such as on the order of 0.5 to 5.0 mm. The glass article  200  has an outer surface  202 . When the glass article  200  is chemically strengthened, such as by placing the glass article  200  in a heated ion bath, ion exchange with other ions present at the outer surface  202  of the glass article. Accordingly, during the chemical strengthening, the ion exchange can be controlled to occur to a determined depth of layer (DoL). The result is an outer strengthened region  204  of the glass article  200 . The amount of chemical strengthening and the depth of the depth of layer (DoL) depends on various criteria including thickness of the glass article  200 , intended usage of the glass article  200 , type of glass, concentration of the ion bath, temperature of the ion bath, and others. As an example, the depth of layer could range from 10-200 μm. 
       FIG. 3  illustrates a glass article  300  according to another embodiment. The glass article  300  has an outer surface  302  and a variable thickness. Unlike  FIG. 2 , the glass article  300  has a variable thickness. In particular, the glass article  300  can include side regions  304  and a middle region  306 . In the example illustrated in  FIG. 3 , the middle region  306  has a thickness that is substantially different from a thickness (t) of the side regions  304 . For example, the thickness of the middle region  306  can be 20-70% of the thickness (t) of the side regions  304 . Typically, the thickness (t) for the glass article  300  depends on its usage. As an example, if the glass article  300  is destined for use as part of a portable electronic device, the thickness tends to be rather thin, such as on the order of 0.3 to 2.0 mm. 
     Nevertheless, if the glass article  300  is chemically strengthened by placing the glass article  300  in a heated ion bath, ion exchange with other ions at the surface  302  of the glass article can occur. The ion exchange occurs to pay determined depth of layer (DL L). Hence, similar to  FIG. 2 , the chemical strengthening serves to strengthen an outer peripheral region  308  of the glass article  300 . In this embodiment, the depth of layer (DoL) is generally uniform across the outer periphery of the glass article  300 . However, since the middle region  306  has a smaller thickness than do the side regions  304 , the depth of layer can be restricted so that the middle region  306  (which is the thinner region) is not placed under too much central tension. Consequently, with respect to the glass article  300 , if chemical strengthening is performed in a uniform fashion such as illustrated in  FIG. 3 , the depth of layer for such chemical strengthening may be unduly limited or not optimized. 
       FIG. 4  is a cross-sectional diagram of a glass article  400  according to still another embodiment. The glass article  400  illustrated in  FIG. 4  has an outer surface  402 . The glass article  400  has a variable thickness in which side regions  404  are thicker than an inner region  406 . In the example illustrated in  FIG. 4 , the middle region  406  has a thickness that is substantially different from a thickness (t) of the side regions  404 . For example, the thickness of the middle region  406  can be 20-70% of the thickness (t) of the side regions  404 . Typically, the thickness (t) for the glass article  400  depends on its usage. As an example, if the glass article  400  is destined for use as part of a portable electronic device, the thickness tends to be rather thin, such as on the order of 0.5 to 5.0 mm. 
     Through chemical strengthening, the glass article  400  can be rendered stronger. Given that the glass article  400  has a variable thickness, the chemical strengthening provided to the different regions can be separately controlled. For example, the chemical strengthening for the different regions can be optimized for it features, characteristics or usage. 
     In the embodiment illustrated in  FIG. 4 , the side regions  404  which are thicker than the middle region  406  can be chemically strengthened to a greater extent than the middle region  406 . Specifically, as depicted in  FIG. 4 , the side regions  404  show that a chemical strengthened region  408  is provided to a first depth of layer (DoL- 1 ), and the middle region  406  shows that a chemical strengthened region  410  has a second depth of layer (DoL- 2 ). As clearly depicted in  FIG. 4 , the first depth of layer (DoL- 1 ) is greater than the second depth of layer (DoL- 2 ). Since the side regions  404  are thicker regions of the glass article  400 , greater amounts of chemical strengthening can be safely provided to the side regions  404 . For the middle portion  406 , chemical strengthening can be performed, but due to its relative thinness, the amount, level or degree of chemical strengthening can be less than that of the side regions  404 . 
     In one embodiment, the ability to separately control the amount of chemical strengthening provided to different regions of glass article, allows chemical strengthening to be optimized on a per region basis. Consequently, a glass article having variable thickness can be chemically strengthened in a manner that optimizes chemical strengthening for each of the distinct regions. 
       FIG. 5  is a flow diagram of a glass strengthening process  500  according to one embodiment. The glass strengthening process  500  is particularly well-suited for strengthening a glass article that has regions of different thickness. For example, the glass strengthening process  500  can yield the glass article  400  shown in  FIG. 4  which has different degree, amount or level of chemically strengthening applied to different regions. 
     The glass strengthening process  500  can initially obtain  502  a glass article that is to be strengthened. The glass article can be configured to have a first region with a first thickness and a second region with a second thickness. In other words, the glass article can be considered to have variable thickness. 
     After the glass article is obtained  502 , a first mask can be applied  504  to the second region of the glass article. The glass article can then be chemically strengthened  506 . More particularly, the first region of the glass article can be chemically strengthened  506 , while the second region is not chemically strengthened. The first mask can serves to inhibit chemical strengthening from being performed with respect to the second region. After the chemical strengthening  506  has concluded, the first mask can be removed  508  from the second region. Then, a second mask can be applied  510  to the first region of the glass article. The second mask can serve to inhibit chemical strengthening from being performed with respect to the first region. 
     After the second mask has been applied  510 , the glass article can again be chemically strengthened  512 . At this point, the second region of the glass article is being chemically strengthened  512 , while the second mask serves to prevent additional chemical strengthening to the first region of the class article. After the chemical strengthening  512  has concluded, the second mask can be removed  514  from the first region. Following the removal  514  of the second mask from the first region, the glass strengthening process  500  can end. 
     Additionally, although not shown, additional post-processing can be performed with respect to the glass member. Still further, the glass article can eventually be used in a consumer electronic device, such as a handheld electronic device where the glass article can form, for example, a portion of said outer housing. 
     Although the first mask and the second mask can be formed such that chemically strengthening is completely blocked by the mask material, it should be understood that the mask material might only reduce chemical strengthening. The masking material can vary, including a metal layer (e.g., foil), polyimide, and the like. Photolithographic patterning or etching can be used to pattern the mask material. The metal layer can, for example, be aluminum. 
       FIGS. 6A-6F  illustrate processing to chemically strengthened a glass article  600 . The processing can correspond to the glass strengthening process  500  illustrated in  FIG. 5 . In  FIG. 6A , the glass article  600  is shown having a variable thickness. The glass article  600  has a thick region  602  with a thickness t 1 , and a thin region  604  having a thickness t 2 . In  FIG. 6B , a mask  606  can then be applied over the thin region  604  of the glass article  600 . Then, as illustrated in  FIG. 6C , upon placing the glass article  600  with the applied mask  606  into a chemical strengthening bath, a peripheral region  608  of the thick region  602  can be chemically strengthened. The chemical strengthening at the peripheral region  608  has a controlled first depth of layer. Following the chemical strengthening that results in the peripheral region  608  of the thick region  602 , the glass article  600  can be removed from the chemical strengthening bath and the mask  606  can be removed. In  FIG. 6D , a second mask  610  can be applied to the thick region  602  of the glass article  600 . Then, as illustrated in  FIG. 6E , upon placing the glass article  600  with the applied second mask  610  into a chemical strengthening bath (which can be the same as the above-described chemical strengthening bath or a new chemical strengthening bath) so that a peripheral region  612  of the thin region  604  can be chemically strengthened. The chemical strengthening of the peripheral region  612  has a second depth of layer. In this example, the second depth of layer is less than the first depth of layer. Following the chemical strengthening that results in the peripheral region  612  of the thin region  604 , the glass article  600  can be removed from the chemical strengthening bath and the mask  610  can be removed. Consequently, as shown in  FIG. 6F , the resulting glass article  600 ′ represents a strengthened version of the glass article  600  in which the thick region  602  is chemically strengthened to a greater extent than the thin region  604 . Advantageously, the different regions of the glass article  600  are able to be chemically strengthened differently for better performance. 
     Following such chemical strengthening, depending on the type of glass, the glass article  600 ′ having a 1 mm thickness can have a central tension (CT) of about 20-100 MPa (Mega Pascals) at a central portion, the peripheral portion  612  can have a peak compressive stress at the surface  602  of about 300-1100 MPa, and the depth of the compressive layer (i.e., depth of layer) can be about 20-150 microns. As examples, the glass article  600 ′ can be formed of aluminosilicate glass or lithium-aluminosilicate glass. In a more specific embodiment, the glass article  600 ′ having a 1 mm thickness can have a central tension (CT) of about 50-60 MPa (Mega Pascals) at a central portion, the peripheral portion  612  can have a peak compressive stress at the surface  602  of about 700-800 MPa, and the depth of the compressive layer (i.e., depth of layer) can be about 50-60 microns for the thick region  602  and about 30-40 microns for the thin region  604 . 
       FIG. 7  is a flow diagram of a glass strengthening process  700  according to another embodiment. The glass strengthening process  700  can initially obtain  702  a glass article to be chemically strengthened. 
     The glass strengthening process  700  is particularly well-suited for strengthening a glass article that has regions of different thickness. For example, the glass strengthening process  700  can yield the glass article  400  shown in  FIG. 4  which has different degree, amount or level of chemically strengthening applied to different regions. 
     In this embodiment, the glass article has at least a plurality of distinct regions, with one of the regions corresponding to a thinner region and another of the regions corresponding to a sticker region. Once the glass article has been obtained  702 , a mask can be applied  704  to the thinner region. Next, the thicker region of the glass article can be chemically strengthened  706 . At this point, the mask that has been applied  704  to the thinner region of the glass article serves to inhibit chemical strengthening of the thinner region. After the chemical strengthening  706  of the thicker region has concluded, the mask can be removed  708  from the thinner region. Thereafter, the glass article, including both the thinner region and the thicker region, can be chemically strengthened  710 . Following the chemical strengthening  710 , the glass strengthening process  700  can end. 
     Additionally, although not shown, additional post-processing can be performed with respect to the glass member. Still further, the glass article can eventually be used in a consumer electronic device, such as a handheld electronic device where the glass article can form, for example, a portion of said outer housing. 
     Although the mask applied  704  to the thinner region can be formed such that chemically strengthening is completely blocked by the mask material. Alternatively, the mask applied  704  to the thicker region can partially block chemical strengthening. The masking material can vary, including a metal layer (e.g., foil), polyimide, and the like. Photolithographic patterning or etching can be used to pattern the mask material. The metal layer can, for example, be aluminum. 
       FIGS. 8A-8E  illustrate processing to chemically strengthened a glass article  800 . The processing can correspond to the glass strengthening process  700  illustrated in  FIG. 7 . In  FIG. 8A , the glass article  800  is shown having a variable thickness. The glass article  800  has a thick region  802  with a thickness t 1 , and a thin region  804  having a thickness t 2 . In  FIG. 8B , a mask  806  can then be applied over the thin region  804  of the glass article  800 . Then, as illustrated in  FIG. 8C , upon placing the glass article  800  with the applied mask  806  into a chemical strengthening bath, a peripheral region  808  of the thick region  802  can be chemically strengthened. The chemical strengthening at the peripheral region  808  has a controlled first depth of layer (DoL- 1 ). Following the chemical strengthening that results in the peripheral region  808  of the thick region  802 , the glass article  800  can be removed from the chemical strengthening bath and the mask  806  can be removed.  FIG. 8C  illustrates the glass article  800  after the chemical strengthening and removal of the mask  806 . 
     Then, as illustrated in  FIG. 8E , upon placing the glass article  800  (with no mask applied) into a chemical strengthening bath (which can be the same as the above-described chemical strengthening bath or a new chemical strengthening bath) so that a peripheral region  808  of the thick region  802  as well as a peripheral region  810  of the thin region  804  can be chemically strengthened. The chemical strengthening of the peripheral region  810  following the subsequent chemical strengthening has a second depth of layer (DoL- 2 ). Additionally, the chemical strengthening of the peripheral region  808  can provide further chemical strengthening to the peripheral region  808  of the thick region  802 . The chemical strengthening of the peripheral region  808  following the subsequent chemical strengthening has a third depth of layer (DoL- 3 ). In this example, the second depth of layer is less than the third depth of layer. Following the subsequent chemical strengthening that results in the peripheral region  810  of the thin region  804  as well as in the peripheral region  808  of the thick region  802 , the glass article  800  can be removed from the chemical strengthening bath. Consequently, as shown in  FIG. 8E , the resulting glass article  800 ′ represents a strengthened version of the glass article  800  in which the thick region  802  is chemically strengthened to a greater extent than the thin region  804 . Advantageously, the different regions of the glass article  800  are able to be chemically strengthened differently for better performance. 
     Following such chemical strengthening, depending on the type of glass, the glass article  800 ′ having a 1 mm thickness can have a central tension (CT) of about 20-100 MPa (Mega Pascals) at a central portion, the peripheral portion  808  can have a peak compressive stress at its surface of about 300-1100 MPa, and the depth of the compressive layer (i.e., depth of layer) can be about 20-150 microns. As examples, the glass article  800 ′ can be formed of aluminosilicate glass or lithium-aluminosilicate glass. In a more specific embodiment, the glass article  800 ′ having a 1 mm thickness can have a central tension (CT) of about 50-60 MPa (Mega Pascals) at a central portion, the peripheral portion  808  can have a peak compressive stress at the surface of about 700-800 MPa, and the depth of the compressive layer (i.e., depth of layer) can be about 50-60 microns for the thick region  802  and about 30-40 microns for the thin region  804 . 
     A glass cover which has undergone a chemical strengthening process generally includes a chemically strengthened layer, as previously mentioned.  FIG. 9A  is a cross-sectional diagram of a glass cover which has been chemically treated such that a chemically strengthened layer is created according to one embodiment. A glass cover  900  includes a chemically strengthened layer  928  and a non-chemically strengthened portion  926 . Although the glass cover  900  is, in one embodiment, subjected to chemical strengthening as a whole, the outer surfaces receive the strengthening. The effect of the strengthening is that the non-chemically strengthened portion  926  is in tension, while the chemically strengthened layer  928  is in compression. While glass cover  900  in  FIG. 9A  is shown as having a rounded edge geometry  902 , it should be appreciated that glass cover  900  may generally have any edge geometry, though rounded geometries at edges may allow for increased strengthening of the edges of glass cover  900 . Rounded edge geometry  902  is depicted by way of example, and not for purposes of limitation. 
       FIG. 9B  is a cross-sectional diagram of a glass cover which has been chemically treated, as shown to include a chemically treated portion in which potassium ions have been implanted according to one embodiment. Chemically strengthened layer  928  has a thickness (y) which may vary depending upon the requirements of a particular system in which glass cover  900  is to be utilized. Non-chemically strengthened portion  926  generally includes Na +  ions  934  but no Alkali metal ions  936 . A chemical strengthening process causes chemically strengthened layer  928  to be formed such that chemically strengthened layer  928  includes both Na +  ions  934  and Alkali metal ions  936 . 
       FIG. 10  is a diagrammatic representation of a chemical treatment process that involves submerging a glass cover in an ion bath according to one embodiment. When glass cover  1000 , which is partially shown in cross-section, is submerged or soaked in a heated ion bath  1032 , diffusion occurs. As shown, Alkali metal ions  1034  (e.g., Sodium (Na)) which are present in glass cover  1000  diffuse into ion bath  1032  while Alkali metal ions  1036  (e.g., potassium (K)) in ion bath  1032  diffuse into glass cover  1000 , such that a chemically strengthened layer  1028  is formed. In other words, Alkali metal ions  1036  from ion bath  1032  can be exchanged with Na +  ions  1034  to form chemically strengthened layer  1028 . Alkali metal ions  1036  typically would not diffuse into a center portion  1026  of glass cover  1000 . By controlling the duration (i.e., time) of a chemical strengthening treatment, temperature and/or the concentration of Alkali metal ions  1036  in ion bath  1032 , the thickness (y) of chemically strengthened layer  1028  may be substantially controlled. 
     The concentration of Alkali metal ions in an ion bath may be varied while a glass cover is soaking in the ion bath. In other words, the concentration of Alkali metal ions in an ion bath may be maintained substantially constant, may be increased, and/or may be decreased while a glass cover is submerged in the ion bath without departing from the spirit or the scope of the present invention. For example, as Alkali metal ions displace Na +  ions in the glass, the Na +  ions become part of the ion bath. Hence, the concentration of Alkali metal ions in the ion bath may change unless additional Alkali metal ions are added into the ion bath. 
     As previously discussed, glass covers can be used as an outer surface of portions of a housing for electronic devices, such as portable electronic devices. Those portable electronic devices that are small and highly portable can be referred to as handheld electronic devices. A handheld electronic device may, for example, function as a media player, phone, internet browser, email unit or some combination of two or more of such. A handheld electronic device generally includes a housing and a display area. 
       FIGS. 11A and 11B  are diagrammatic representations of electronic device  1100  according to one embodiment.  FIG. 11A  illustrates a top view for the electronic device  1100 , and  FIG. 11B  illustrates a cross-sectional side view for electronic device  1100  with respect to reference line A-A′. Electronic device  1100  can include housing  1102  that has glass cover window  1104  (glass cover) as a top surface. Cover window  1104  is primarily transparent so that display assembly  1106  is visible through cover window  1104 . Cover window  1104  can be chemically strengthened using the multi-bath chemical processing described herein. Display assembly  1106  can, for example, be positioned adjacent cover window  1104 . Housing  1102  can also contain internal electrical components besides the display assembly, such as a controller (processor), memory, communications circuitry, etc. Display assembly  1106  can, for example, include a LCD module. By way of example, display assembly  1106  may include a Liquid Crystal Display (LCD) that includes a Liquid Crystal Module (LCM). In one embodiment, cover window  1104  can be integrally formed with the LCM. Housing  1102  can also include an opening  1108  for containing the internal electrical components to provide electronic device  1100  with electronic capabilities. In one embodiment, housing  1102  need not include a bezel for cover window  1104 . Instead, cover window  1104  can extend across the top surface of housing  1102  such that the edges of cover window  1104  can be aligned (or substantially aligned) with the sides of housing  1102 . The edges of cover window  1104  can remain exposed. Although the edges of cover window  1104  can be exposed as shown in  FIGS. 11A and 11B , in alternative embodiment, the edges can be further protected. As one example, the edges of cover window  1104  can be recessed (horizontally or vertically) from the outer sides of housing  1102 . As another example, the edges of cover window  1104  can be protected by additional material placed around or adjacent the edges of cover window  1104 . 
     Cover window  1104  may generally be arranged or embodied in a variety of ways. By way of example, cover window  1104  may be configured as a protective glass piece that is positioned over an underlying display (e.g., display assembly  1106 ) such as a flat panel display (e.g., LCD) or touch screen display (e.g., LCD and a touch layer). Alternatively, cover window  1104  may effectively be integrated with a display, i.e., glass window may be formed as at least a portion of a display. Additionally, cover window  1104  may be substantially integrated with a touch sensing device such as a touch layer associated with a touch screen. In some cases, cover window  1104  can serve as the outer most layer of the display. 
       FIGS. 12A and 12B  are diagrammatic representations of electronic device  1200  according to another embodiment.  FIG. 12A  illustrates a top view for electronic device  1200 , and  FIG. 12B  illustrates a cross-sectional side view for electronic device  1200  with respect to reference line B-B′. Electronic device  1200  can include housing  1202  that has glass cover window  1204  (glass cover) as a top surface. In this embodiment, cover window  1204  can be protected by side surfaces  1203  of housing  1202 . Here, cover window  1204  does not fully extend across the top surface of housing  1202 ; however, the top surface of side surfaces  1203  can be adjacent to and aligned vertically with the outer surface of cover window  1204 . Since the edges of cover window  1204  can be rounded for enhanced strength, there may be gaps  1205  that are present between side surfaces  1203  and the peripheral edges of cover window  1204 . Gaps  1205  are typically very small given that the thickness of cover window  1204  is thin (e.g., less than 3 mm). However, if desired, gaps  1205  can be filled by a material. The material can be plastic, rubber, metal, etc. The material can conform in gap  1205  to render the entire front surface of electronic device  1200  flush, even across gaps  1205  proximate the peripheral edges of cover window  1204 . The material filling gaps  1205  can be compliant. The material placed in gaps  1205  can implement a gasket. By filling the gaps  1205 , otherwise probably undesired gaps in the housing  1202  can be filled or sealed to prevent contamination (e.g., dirt, water) forming in the gaps  1205 . Although side surfaces  1203  can be integral with housing  1202 , side surface  1203  could alternatively be separate from housing  1202  and, for example, operate as a bezel for cover window  1204 . 
     Cover window  1204  is primarily transparent so that display assembly  1206  is visible through cover window  1204 . Display assembly  1206  can, for example, be positioned adjacent cover window  1204 . Housing  1202  can also contain internal electrical components besides the display assembly, such as a controller (processor), memory, communications circuitry, etc. Display assembly  1206  can, for example, include a LCD module. By way of example, display assembly  1206  may include a Liquid Crystal Display (LCD) that includes a Liquid Crystal Module (LCM). In one embodiment, cover window  1204  is integrally formed with the LCM. Housing  1202  can also include an opening  1208  for containing the internal electrical components to provide electronic device  1200  with electronic capabilities. 
     The front surface of electronic device  1200  can also include user interface control  1208  (e.g., click wheel control). In this embodiment, cover window  1204  does not cover the entire front surface of electronic device  1200 . Electronic device  1200  essentially includes a partial display area that covers a portion of the front surface. 
     Cover window  1204  may generally be arranged or embodied in a variety of ways. By way of example, cover window  1204  may be configured as a protective glass piece that is positioned over an underlying display (e.g., display assembly  1206 ) such as a flat panel display (e.g., LCD) or touch screen display (e.g., LCD and a touch layer). Alternatively, cover window  1204  may effectively be integrated with a display, i.e., glass window may be formed as at least a portion of a display. Additionally, cover window  1204  may be substantially integrated with a touch sensing device such as a touch layer associated with a touch screen. In some cases, cover window  1204  can serve as the outer most layer of the display. 
     As noted above, the electronic device can be a handheld electronic device or a portable electronic device. The invention can serve to enable a glass cover to be not only thin but also adequately strong. Since handheld electronic devices and portable electronic devices are mobile, they are potentially subjected to various different impact events and stresses that stationary devices are not subjected to. As such, the invention is well suited for implementation of glass surfaces for handheld electronic device or a portable electronic device that are designed to be thin. 
     The strengthened glass, e.g., glass covers or cover windows, is particularly useful for thin glass applications. For example, the thickness of a glass cover being strengthened can be between about 0.5-2.5 mm. In other embodiments, the strengthening is suitable for glass products whose thickness is less than about 2 mm, or even thinner than about 1 mm, or still even thinner than about 0.6 mm. 
     Chemically strengthening glass, e.g., glass covers or cover windows, can be more effective for edges of glass that are rounded by a predetermined edge geometry having a predetermined curvature (or edge radius) of at least 10% of the thickness applied to the corners of the edges of the glass. In other embodiments, the predetermined curvature can be between 20% to 50% of the thickness of the glass. A predetermined curvature of 50% can also be considered a continuous curvature, one example of which is illustrated in  FIG. 3E . 
     In one embodiment, the size of the glass cover depends on the size of the associated electronic device. For example, with handheld electronic devices, the size of the glass cover is often not more than five (5) inches (about 12.7 cm) diagonal. As another example, for portable electronic devices, such as smaller portable computers or tablet computers, the size of the glass cover is often between four (4) (about 10.2 cm) to twelve (12) inches (about 30.5 cm) diagonal. As still another example, for portable electronic devices, such as full size portable computers, displays (including televisions) or monitors, the size of the glass cover is often between ten (10) (about 25.4 cm) to twenty (20) inches (about 50.8 cm) diagonal or even larger. 
     However, it should be appreciated that with larger screen sizes, the thickness of the glass layers may need to be greater. The thickness of the glass layers may need to be increased to maintain planarity of the larger glass layers. While the displays can still remain relatively thin, the minimum thickness can increase with increasing screen size. For example, the minimum thickness of the glass cover can correspond to about 0.3 mm for small handheld electronic devices, about 0.5 mm for smaller portable computers or tablet computers, about 1.0 mm or more for full size portable computers, displays or monitors, again depending on the size of the screen. However, more generally, the thickness of the glass cover can depend on the application and/or the size of electronic device. 
     As discussed above, glass cover or, more generally, a glass piece may be chemically treated such that surfaces of the glass are effectively strengthened. Through such strengthening, glass pieces can be made stronger so that thinner glass pieces can be used with consumer electronic device. Thinner glass with sufficient strength allows for consumer electronic device to become thinner. 
     The techniques describe herein may be applied to glass surfaces used by any of a variety of electronic devices including but not limited handheld electronic devices, portable electronic devices and substantially stationary electronic devices. Examples of these include any known consumer electronic device that includes a display. By way of example, and not by way of limitation, the electronic device may correspond to media players, mobile phones (e.g., cellular phones), PDAs, remote controls, notebooks, tablet PCs, monitors, all in one computers and the like. 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     Additional details on strengthening edges of glass articles and/or different chemical baths can be found in: (i) U.S. Provisional Patent Application No. 61/156,803, filed Mar. 2, 2009 and entitled “TECHNIQUES FOR STRENGTHENING GLASS COVERS FOR PORTABLE ELECTRONIC DEVICES”, which is herein incorporated by reference; (ii) International Patent Application No. PCT/US2010/025979, filed Mar. 2, 2010 and entitled “Techniques for Strengthening Glass Covers for Portable Electronic Devices”, which is herein incorporated by reference; (iii) U.S. Provisional Patent Application No. 61/374,988, filed Aug. 18, 2010, and entitled “ENHANCED STRENGTHING OF GLASS”, which is hereby incorporated herein by reference; (iv) U.S. patent application Ser. No. 12/895,823, filed Sep. 30, 2010 and entitled “ENHANCED STRENGTHENING OF GLASS”; (v) U.S. patent application Ser. No. 12/895,372, filed Sep. 30, 2010 and entitled “TECHNIQUES FOR STRENGTHENING GLASS COVERS FOR PORTABLE ELECTRONIC DEVICES”, which is herein incorporated by reference; (vi) U.S. patent application Ser. No. 12/895,393, filed Sep. 30, 2010 and entitled “TECHNIQUES FOR STRENGTHENING GLASS COVERS FOR PORTABLE ELECTRONIC DEVICES”, which is herein incorporated by reference; (vii) U.S. Provisional Patent Application No. 61/301,585, filed Feb. 4, 2010 and entitled “TECHNIQUES FOR STRENGTHENING GLASS COVERS FOR PORTABLE ELECTRONIC DEVICES,” which is hereby incorporated herein by reference; (viii) U.S. Provisional Patent Application No. 61/410,290, filed Nov. 4, 2010, and entitled “ENHANCED STRENGTHING OF GLASS”, which is hereby incorporated herein by reference; (ix) PCT International Application No. PCT/US2011/023499, filed Feb. 2, 2011, and entitled “ENHANCED CHEMICAL STRENGTHENING GLASS OF COVERS FOR PORTABLE ELECTRONIC DEVICES”, which is hereby incorporated herein by reference; (x) U.S. patent application Ser. No. 12/847,926, filed Jul. 30, 2010, and entitled “ELECTRONIC DEVICE HAVING SELECTIVELY STRENGTHENING GLASS COVER GLASS”, which is hereby incorporated herein by reference; (xi) U.S. Provisional Patent Application No. 61/453,404, filed Mar. 16, 2011, and entitled “ELECTRONIC DEVICE HAVING SELECTIVELY STRENGTHENED GLASS”, which is hereby incorporated herein by reference; (xii) U.S. patent application Ser. No. 13/235,090, filed concurrently, and entitled “ELECTRONIC DEVICE HAVING SELECTIVELY STRENGTHENED GLASS”, which is hereby incorporated herein by reference. 
     Although only a few embodiments of the invention have been described, it should be understood that the invention may be embodied in many other specific forms without departing from the spirit or the scope of the present invention. By way of example, the steps associated with the methods of the invention may vary widely. Steps may be added, removed, altered, combined, and reordered without departing from the spirit of the scope of the invention. Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. 
     While this specification contains many specifics, these should not be construed as limitations on the scope of the disclosure or of what may be claimed, but rather as descriptions of features specific to particular embodiment of the disclosure. Certain features that are described in the context of separate embodiments can also be implemented in combination. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. 
     While this invention has been described in terms of several embodiments, there are alterations, permutations, and equivalents, which fall within the scope of this invention. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention.

Metadata:
Filing Date: 20110916
Publication Date: 20200922
Grant Date: 20200922
Priority Date: 20110316
Inventors: Weber, Douglas J.
Assignee: APPLE INC
CPC Classifications: [{"code": "C03C21/002", "inventive": true, "first": true, "tree": "[]"}, {"code": "C03C21/002", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 46828291