Innovation for Impact #9: Lead-free, high-tech glass for the semiconductor industry

The semiconductor industry is crucial for Switzerland as it powers key technologies in sectors like telecommunications, healthcare, and automotive. Switzerland contributes significantly through its expertise in precision manufacturing and research, particularly in high-tech components. As semiconductors enable innovations such as artificial intelligence and renewable energy, their importance is central to technological advancement and economic growth.

Exceptional precision is required in the semiconductor industry, especially in the manufacturing of tiny computer chips and components under severe conditions. These conditions often involve temperature extremes, vacuums, or harsh acids. Sensors are crucial to monitor and ensure the proper environment, so they must endure these tough conditions.

Innosuisse project ThreeFree:

Developing lead-free glass sealing for next-gen drift-free and stress-free high-vacuum gauges

Withstanding adverse environments presents a challenge for suppliers like the Swiss manufacturer of sensitive vacuum sensors, INFICON .

Previously, Inficon used a durable lead-containing glass to connect sensor components. However, EU regulations (e.g. REACH 191) and/or local legislations are becoming stricter in their policy towards the use of lead. In an Innosuisse project, researchers led by Gurdial Blugan from the Laboratory for High Performance Ceramics at Empa , successfully developed a lead-free glass that meets the demanding standards. They also set up a new process capability (including quench furnace) to develop glasses from starting powder to the final sealing product and characterization of the key performance properties.

In addition, the researchers also created new methods to precisely characterize this glass. After the successful completion of the initial project, the partners have begun working on a follow-up project to improve the high-tech glass even further.

The developed glasses have also been tested for joining in other applications, e.g. metal to ceramic in batteries in the LISA project (Laser Joining of ceramic-metal in SaltBatteries) with Saleon AG , and have proven to show excellent properties. In future, these glasses may be used for a wide range of joining applications for very harsh environmental conditions.

Key achievements:

• Collaboration with Empa: Inficon approached Empa after unsuccessful attempts to find alternatives, leading to a fruitful partnership.
• Lead-free glass development: Inficon and Empa successfully developed a lead-free glass to replace lead-containing glass, meeting industry standards.
• Precise characterization methods: New methods were created to characterize the properties of the lead-free glass.
• Ongoing improvements: A follow-up project has started to further enhance the performance of the new glass.

Further reading

LISA: Innosuisse funding for battery research