Vacuum glass and construction method of internal support and edge sealing object of vacuum glass
By using inorganic materials with low thermal conductivity and low melting point glass brazing layer in vacuum glass, a "broken bridge" structure is formed, which solves the problem of difference in thermal bridge effect and expansion coefficient, improves thermal insulation and sound insulation performance, and reduces the Cost and electricity bills extend the service life.
Patent Information
- Application Number
- CN202411128232.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-16
- Publication Date
- 2024-12-31
AI Technical Summary
The internal support and edge sealing structure of the existing vacuum glass have problems such as thermal bridge effect, deformation caused by the difference in material expansion coefficient, and high power consumption of high temperature sealing, which affects its thermal insulation, sound insulation and service life.
Inorganic materials with a thermal conductivity lower than ordinary glass are used as internal support, and low-melting point glass brazing layer and buffer insulation layer are used at the edge sealing, combining getter and weather-resistant glue to form a "broken bridge" structure To reduce heat conduction and reduce sealing temperature by preheating and drying.
It improves the thermal insulation and sound insulation performance of vacuum glass, reduces costs and electricity bills, and extends service life and enhances airtightness and watertightness.
Smart Images
Figure CN119219347A_ABST
Abstract
Description
Technical Field
[0001] The present invention mainly relates to the technical field of vacuum glass new material manufacturing, and specifically is a method for constructing vacuum glass and its internal supports and edge sealants. Background Art
[0002] Vacuum glass is made by separating two pieces of flat glass (usually one is white float glass and the other is low-emissivity coated glass) with tiny supports ranging from 25mm×25mm to 60mm×60mm. The height of the supports is usually less than 0.5mm. The periphery is welded and sealed with inorganic materials, and the air is evacuated under high temperature to form a high vacuum cavity of more than 10-1Pa, finally forming a glass product similar to a transparent flat thermos.
[0003] Vacuum glass is derived from the principle of thermos. Due to the thin air in the vacuum layer, it isolates the conduction and convection of heat to a certain extent. At the same time, the glass surface is coated with a low-emissivity coating to reduce radiant heat. Due to the lack of air medium in the vacuum layer, sound is difficult to propagate. It is an integrated innovation of cathode ray tubes and related glass deep processing technologies. Its thermal insulation performance is 10 times that of ordinary single-piece glass and 3-5 times that of insulating glass (calculated based on the heat transfer coefficient). The sound insulation reaches more than 35 decibels, the service life is more than 25 years, and the thickness is only 1 / 3 of ordinary insulating glass.
[0004] The internal support and edge sealing structures (methods) of existing vacuum glass at home and abroad are mainly divided into two types: 1. Internal support structure (method) 1.1 Use metal or metal alloy, such as stainless steel, aluminum alloy, ferromagnetic alloy and other materials, processed into sheet, ring, C shape, etc., and placed manually or mechanically as the support for the internal spacing of two pieces of glass.
[0005] 1.2 Use inorganic non-metals, such as ceramic glazes, glass glazes, etc., through dispensing or printing, and solidify after glass preheating or tempering heating, as a support for the internal spacing of two pieces of glass.
[0006] 2. Edge sealing structure (method) 2.1 Metal sealing: It mainly uses indium or other metal compounds with a low melting point. The welding temperature is generally around 300°C. The metal compounds pre-coated on the edges of the two pieces of glass are melted and solidified in an electric heating furnace to complete the metal welding and sealing of the two pieces of glass.
[0007] 2.2 Low-melting-point glass powder sealing: It mainly uses low-melting-point glass powder solder doped with lead (melting point 327.5℃). The welding temperature is generally around 400℃. The low-melting-point glass powder pre-coated on the edges of the two pieces of glass is melted and solidified in an electric heating furnace to complete the glass powder brazing and sealing of the two pieces of glass.
[0008] The main problems or shortcomings of the technical solutions of the existing internal support and edge sealing structure (method) of vacuum glass are: 3. Internal support structure (method) 3.1 Using pure metal or metal alloy as internal support, the thermal conductivity of the material is much higher than that of glass, which is easy to form "heat bridge" penetration, resulting in the decline of thermal insulation and sound insulation performance of vacuum glass. In addition, when metal supports are placed on the smooth glass surface, it is easy to cause displacement, omission, overlap and other problems that affect quality, output and efficiency. If the metal supports are fixed with adhesive in advance, the adhesive is easy to volatilize and carbonize when encountering high temperature sealing, affecting the vacuum environment and vacuum equipment pipelines.
[0009] 3.2 Inorganic non-metallic materials, mainly ceramic glazes and glass glazes, are used as internal supports. The thermal conductivity of these materials is basically close to that of glass. Usually, many such supports (about 300-1000) are placed within 1㎡, which is also a weak point for heat conduction between two pieces of glass. In addition, ceramic or glass glazes are also brittle materials after high-temperature curing. When the flatness of the original glass sheet is poor, or the height consistency of the batch of glazes is poor, or the flatness of the original glass sheet deteriorates after tempering, it is easy to cause uneven force on each support under high vacuum pressure, resulting in bursting (explosion point) phenomenon.
[0010] Special note: After the vacuum glass products are formed, no matter what kind of support has quality problems, it cannot be repaired or replaced because it is welded inside.
[0011] 4. Edge sealing structure (method) 4.1 Metal sealing: using indium or other metal compounds with low melting points, the cost is high, usually more than 3 times that of low melting point glass powder. In addition, metal and glass are two different materials after all, and the expansion coefficients of the materials are quite different, and the stress is different. Especially in the outdoor environment, the edge is easily cracked, deformed and displaced by the temperature difference between indoor and outdoor and the shear force of wind pressure, resulting in vacuum failure (air intake).
[0012] 4.2 Low-melting-point glass powder sealing: The sealing temperature of about 400°C is relatively high, consumes more electricity, and easily affects the tempering performance (annealing) of the glass.
[0013] Special note: Whether metal or low-melting-point glass powder is used for sealing, it is a rigid connection. The national standard "Vacuum Glass" GB / T38586-2020 stipulates that the effective edge sealing width should be greater than 5mm. If the connection points are not fully in contact during processing and product application, they are prone to deformation and displacement due to temperature differences and wind pressure, resulting in vacuum failure. Summary of the invention
[0014] In order to solve the deficiencies of the prior art, the present invention provides a method for constructing vacuum glass and its internal supports and edge seals, which has the characteristics of improving the thermal insulation, sound insulation, anti-frost and condensation, and service life of the vacuum glass.
[0015] In order to achieve the above object, the present invention is implemented through the following technical solutions: A method for constructing vacuum glass and its internal support and edge sealing, comprising an outer glass layer and an intermediate layer, characterized in that: the outer glass layer comprises two outer glass layers, an intermediate layer is arranged between the two glass layers, the intermediate layer comprises a vacuum layer, an internal support structure, and an edge sealing structure, the edge sealing structure is arranged at the edge of the intermediate layer, the internal support structure is evenly distributed in the intermediate layer inside the edge sealing structure, and the space in the intermediate layer where the internal support structure and the edge sealing structure are not in contact is a vacuum layer; The internal support structure includes a support material buffer insulation layer and a ceramic or glass glaze layer, wherein the ceramic or glass glaze layer is arranged on the surface where the support material buffer insulation layer contacts the glass layers on both sides; The edge sealing structure comprises a sealing material buffer insulation layer, a low-melting-point glass soldering layer, a getter, butyl rubber, polysulfide rubber or silicone rubber, wherein the low-melting-point glass soldering layer is arranged on the surface where the sealing material buffer insulation layer contacts the glass layers on both sides, and the outside of the sealing material buffer insulation layer is filled with a getter, butyl rubber, polysulfide rubber or silicone rubber in sequence; The ceramic or glass glaze is concave after being dispensed and molded, and corresponds to the top and bottom, and is cured by heating during glass pretreatment or tempering; The supporting material is composed of an inorganic material having a lower thermal conductivity than ordinary flat glass and having a certain supporting strength, elasticity and flexibility, including but not limited to insulating foam glass balls and optical glass micro beads; After the buffer insulation layer of supporting material is filled in the middle of the upper and lower concave shapes, the upper and lower ceramic or glass glaze layers shall not be in direct contact under the rated vacuum pressure, so that the middle layer forms a heat-conducting "broken bridge" effect to reduce heat conduction; The low-melting-point glass brazing layer is composed of a low-melting-point glass powder brazing material doped with tin. After the low-melting-point glass powder brazing material is coated on the four edges of the glass, it is usually preheated and dried, and then sent to a vacuum sealing furnace. While vacuuming and continuously undergoing the heating, heat preservation, and cooling processes, the upper and lower low-melting-point glass brazing layers are melted and combined with the two contact surfaces of the sealing material buffer insulation layer, and the upper and lower edges of the two pieces of glass in contact are also brazed, sealed, and solidified; The sealing material buffer insulation layer is composed of an inorganic material having an expansion coefficient similar to that of a low-melting-point glass powder solder, a thermal conductivity lower than that of ordinary flat glass, and having certain supporting strength, elasticity and flexibility, including but not limited to insulating foam glass powder and BK7 optical glass powder; After completing the inorganic material sealing of the vacuum glass edge, a layer of getter is first applied through the reserved edge space to further absorb excess air at the edge and extend the service life of the vacuum glass; then a second layer of sealing with organic materials is applied, using weather-resistant butyl glue, polysulfide glue or silicone glue verified by insulating glass to further enhance the airtightness, watertightness and other sealing and weather resistance properties of the vacuum glass; In the initial stage, the height of the internal support structure should be slightly higher than the edge sealing structure. Under the action of vacuum pressure and auxiliary clamps, the height of the internal support structure gradually becomes level with the edge sealing structure. As the edge sealing material gradually melts and solidifies, the two glass layers are completely sealed.
[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. The product is more energy-efficient. The "broken bridge" treatment is used in the internal support structure and edge sealing structure to improve the thermal insulation and sound insulation performance of the product.
[0017] 2. The product is more environmentally friendly and cost-saving. In the sealing material, tin is used to replace lead, and the sealing temperature can be reduced to below 300°C, saving electricity costs.
[0018] 3. The product is safer. Due to the use of a new "sandwich" structure and materials for internal support and edge sealing, its expansion coefficient is close to that of glass, and it has certain support strength, elasticity and flexibility, so it can effectively prevent the problems of wind pressure resistance and expansion and cracking of vacuum glass, and increase its service life. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Figure 1 It is a schematic diagram of the cross-sectional structure of the present invention; Figure 2 It is a schematic diagram of the structure of insulating glass in the prior art; Figure 3 It is a schematic diagram of the vacuum glass structure in the prior art.
[0020] The numbers shown in the accompanying drawings are: 1. glass layer; 2. vacuum layer; 3. ceramic or glass glaze layer; 4. supporting material buffer insulation layer; 5. low-melting point glass brazing layer; 6. sealing material buffer insulation layer; 7. getter; 8. butyl rubber; 9. polysulfide rubber or silicone rubber. DETAILED DESCRIPTION
[0021] The present invention will be further described with reference to the accompanying drawings and specific embodiments. It should be understood that these embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention. In addition, it should be understood that after reading the content taught by the present invention, those skilled in the art may make various changes or modifications to the present invention, and these equivalent forms also fall within the scope limited by the application.
[0022] Combined with Figure 1-Figure 3 , a method for constructing vacuum glass and its internal support and edge sealing, comprising an outer glass layer and an intermediate layer, wherein the outer glass layer comprises two outer glass layers 1, an intermediate layer is arranged between the two glass layers 1, the intermediate layer comprises a vacuum layer 2, an internal support structure, and an edge sealing structure, the edge sealing structure is arranged at the edge of the intermediate layer, the internal support structure is evenly distributed in the intermediate layer inside the edge sealing structure, and the space in the intermediate layer where the internal support structure and the edge sealing structure are not in contact is a vacuum layer; the material of the glass layer includes but is not limited to glass substrates such as flat glass, tempered glass, and coated glass; The internal support structure comprises a support material buffer insulation layer 4 and a ceramic or glass glaze layer 3, wherein the ceramic or glass glaze layer 3 is arranged on the surface of the support material buffer insulation layer 4 in contact with the glass layers 1 on both sides; the ceramic or glass glaze layer (3) shall not completely wrap the buffer insulation layer (4); The edge sealing structure comprises a sealing material buffer insulation layer 6, a low-melting-point glass soldering layer 5, a getter 7, a butyl rubber 8, a polysulfide rubber or a silicone rubber 9, wherein the low-melting-point glass soldering layer 5 is arranged on the surface where the sealing material buffer insulation layer 6 contacts the glass layers 1 on both sides, and the outside of the sealing material buffer insulation layer 6 is filled with a getter 7, a butyl rubber 8, a polysulfide rubber or a silicone rubber 9 in sequence; The ceramic or glass glaze is concave after being dispensed (coated or printed) and molded, and corresponds to the top and bottom, and is cured by heating during glass pretreatment or tempering; The supporting material is composed of an inorganic material having a lower thermal conductivity than ordinary flat glass (thermal conductivity 1.05-1.2 W / m‧K) and having a certain supporting strength, elasticity and flexibility, including but not limited to insulating foam glass balls (thermal conductivity less than 0.04-0.6 W / m‧K) and optical glass microbeads (thermal conductivity 0.2-0.9 W / m‧K); After the upper and lower concave shapes are filled with the supporting material buffer insulation layer 4 in the middle, the upper and lower ceramic or glass glaze layers 3 shall not be in direct contact under the rated vacuum pressure of 10-1Pa-10-4Pa, so that the middle layer forms a heat-conducting "broken bridge" effect to reduce heat conduction; although the upper and lower ceramic or glass glaze layers 3 are in direct contact with the supporting material buffer insulation layer 4, they are independent of each other and are not fused into one and tightly combined; The low-melting-point glass brazing layer 5 is composed of a low-melting-point glass powder brazing material doped with tin (melting point 231.9). After the low-melting-point glass powder brazing material is coated on the four edges of the glass, it is usually preheated and dried, and then sent to a vacuum sealing furnace. While vacuuming and continuously undergoing the heating, heat preservation, and cooling processes, the upper and lower low-melting-point glass brazing layers 5 and the two contact surfaces of the sealing material buffer insulation layer 6 are melted and combined, and the upper and lower glass edges that are in contact are also brazed, sealed, and solidified; The sealing material buffer insulation layer 6 is composed of an inorganic material having an expansion coefficient similar to that of low-melting-point glass powder solder (expansion coefficient of about 7.6×10-6 / ℃), a thermal conductivity lower than that of ordinary flat glass (expansion coefficient of about 8.5×10-6 / ℃), and having certain supporting strength, elasticity and flexibility, including but not limited to insulating foam glass powder (expansion coefficient of 5-10×10-6 / ℃), BK7 optical glass powder (expansion coefficient of 7.1×10-6 / ℃); Special note: In the vacuum sealing furnace, the upper and lower low-melting-point glass brazing layers are melted and combined with the four peripheral edges of the two pieces of glass and the two contact surfaces of the middle insulation layer at the same time to ensure the overall sealing effect.
[0023] After completing the inorganic material sealing of the vacuum glass edge, a layer of getter is first applied through the reserved edge space to further absorb excess air at the edge and extend the service life of the vacuum glass; then a second layer of sealing with organic materials is applied, using weather-resistant butyl glue, polysulfide glue or silicone glue verified by insulating glass to further enhance the airtightness, watertightness and other sealing and weather resistance properties of the vacuum glass; In the initial stage, the height of the internal support structure should be slightly higher than the edge sealing structure. Under the action of vacuum pressure and auxiliary clamps, the height of the internal support structure gradually becomes level with the edge sealing structure. As the edge sealing material gradually melts and solidifies, the two glass layers 1 are completely sealed.
[0024] Working principle: By using a material with a lower thermal conductivity than the upper and lower layers (segments) in the internal supporting middle layer (segment), the conduction of heat can be effectively prevented, thus forming a heat-insulating "broken bridge" structure.
[0025] By using a material with an expansion coefficient close to that of the low-melting-point glass powder solder in the middle layer (segment) of the edge seal, problems such as thermal expansion and contraction, as well as stress concentration, can be effectively prevented, thus preventing the glass edge from breaking during use.
[0026] By using inorganic materials with certain supporting strength, elasticity and flexibility in the middle layer (segment), while ensuring the supporting strength of the interior and edges of the vacuum glass, the destructiveness of wind pressure, stress, etc. on rigid connecting components is reduced.
[0027] Working or running steps: 1. On the surface of two pieces of glass, glue (coat or print) ceramic or glass glaze layers at a certain distance. The layers are processed into concave shapes, corresponding to each other up and down.
[0028] 2. Use a glass preheating furnace or a tempering furnace to heat, solidify and shape the glaze.
[0029] 3. According to the concave size of the glaze, process the intermediate of the internal support (buffering and insulation layer of the support material).
[0030] 4. Apply low-melting-point glass powder solder around the edges of the two pieces of glass.
[0031] 5. Carry out a certain drying treatment on the glass powder solder in a wet state.
[0032] 6. Place the intermediate body of the internal support in a piece of glass concave glaze.
[0033] 7. Position and close the upper and lower glass sheets. At this time, the internal support material is slightly higher than the edge sealing material, and both glass sheets are open all around.
[0034] 8. Pour (apply) the sealing material intermediate around the edges of the two pieces of glass to achieve a preliminary seal between the two pieces of glass.
[0035] 9. Send the vacuum glass semi-finished products into the vacuum sealing furnace, evacuate the vacuum step by step, and control the heating, heat preservation and cooling process at the same time.
[0036] 10. When the vacuum sealing furnace cools down to about 70℃, open the furnace door and output the finished product.
[0037] Further improvement methods: 1. Perform pre-treatment such as flat grinding and polishing on the surfaces of the two pieces of glass to further eliminate the hidden dangers of micro-cracks and scratches and improve the flatness of the glass surface.
[0038] 2. Apply a layer of transparent heat-insulating paint on each piece of glass to further enhance the heat-insulating performance of the glass.
[0039] Cutting, edge grinding and cleaning of original glass; point distribution (placing support objects), tempering (heat treatment), powder distribution (placing edge sealing material glass powder), assembly, vacuum sealing and finished product inspection.
[0040] Note: In a vacuum furnace, vacuuming and heating are performed simultaneously, which is commonly known as the "one-step method".
[0041] The edge sealing is first heated in a sealing furnace, and then vacuum is drawn in a vacuum furnace through the reserved exhaust holes on the glass surface or edge, commonly known as the "two-step method".
[0042] This method has the characteristics of improving the thermal insulation, sound insulation, anti-frost and condensation, and service life of vacuum glass. It is suitable for green buildings (new energy-saving buildings and doors and windows of existing buildings for energy-saving renovation); energy-saving home appliances (doors of refrigerators, freezers, refrigerators, wine cabinets, etc.); transportation (doors and windows of automobiles, especially new energy vehicles, subways, high-speed railways, ships, etc.); solar photovoltaic base plates (due to the characteristics of thermal insulation, sound insulation and transparency, they are suitable for photovoltaic building integration BIPV); agricultural greenhouses and other fields.
[0043] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims
1. A vacuum glass comprising an outer glass layer and an intermediate layer, characterized in that: The outer glass layer comprises two outer glass layers (1), an intermediate layer is arranged between the two glass layers (1), the intermediate layer comprises a vacuum layer (2), an internal support structure, and an edge sealing structure, the edge sealing structure is arranged at the edge of the intermediate layer, the internal support structure is evenly distributed in the intermediate layer inside the edge sealing structure, and the space in the intermediate layer where the internal support structure and the edge sealing structure are not in contact is a vacuum layer.
2. A vacuum glass according to claim 1, characterized in that: The internal support structure comprises a support material buffer insulation layer (4) and a ceramic or glass glaze layer (3), wherein the ceramic or glass glaze layer (3) is arranged on the surface of the support material buffer insulation layer (4) in contact with the glass layers (1) on both sides.
3. The vacuum glass according to claim 1, characterized in that: The edge sealing structure comprises a sealing material buffer insulation layer (6), a low melting point glass soldering layer (5), a getter (7), butyl rubber (8), polysulfide rubber or silicone rubber (9), wherein the low melting point glass soldering layer (5) is arranged on the surface of the sealing material buffer insulation layer (6) in contact with the glass layers (1) on both sides, and the outside of the sealing material buffer insulation layer (6) is filled with the getter (7), butyl rubber (8), polysulfide rubber or silicone rubber (9) in sequence.
4. A method for constructing an internal support and an edge seal of a vacuum glass, characterized in that: The ceramic or glass glaze is concave after being dispensed and molded, and corresponds to the top and bottom, and is cured by heating during glass pretreatment or tempering; The supporting material is composed of an inorganic material having a lower thermal conductivity than ordinary flat glass and having a certain supporting strength, elasticity and flexibility, including but not limited to insulating foam glass balls and optical glass micro beads; After the support material buffer insulation layer (4) is filled in the middle of the upper and lower concave shapes, the upper and lower ceramic or glass glaze layers (3) must not be in direct contact under the rated vacuum pressure, so that the middle layer forms a heat-conducting "broken bridge" effect to reduce heat conduction; The low-melting-point glass soldering layer (5) is composed of a low-melting-point glass powder solder doped with tin. After the low-melting-point glass powder soldering material is coated on the four edges of the glass, it is usually preheated and dried, and then sent to a vacuum sealing furnace. While evacuating and continuously undergoing the heating, heat preservation and cooling processes, the upper and lower low-melting-point glass soldering layers (5) are melted and bonded to the two contact surfaces of the sealing material buffer insulation layer (6), and the upper and lower edges of the two pieces of glass in contact are also brazed, sealed and solidified. The sealing material buffer insulation layer (6) is composed of an inorganic material having an expansion coefficient similar to that of a low-melting-point glass powder solder, a thermal conductivity lower than that of ordinary flat glass, and having a certain supporting strength, elasticity and flexibility, including but not limited to insulating foam glass powder and BK7 optical glass powder.
5. A method for constructing an internal support and an edge seal of a vacuum glass according to claim 4, characterized in that: After completing the inorganic material sealing at the edge of the vacuum glass, a layer of getter is first applied through the reserved edge space to further absorb excess air at the edge and extend the service life of the vacuum glass; then a second seal of organic material is applied, using weather-resistant butyl glue, polysulfide glue or silicone glue that has been verified by insulating glass, to further enhance the airtightness, watertightness and weather resistance of the vacuum glass.
6. The method for constructing an internal support and an edge seal of a vacuum glass according to claim 4, characterized in that: In the initial stage, the height of the internal support structure should be slightly higher than the edge sealing structure. Under the action of vacuum pressure and the auxiliary clamp, the height of the internal support structure gradually becomes level with the edge sealing structure. As the edge sealing material gradually melts and solidifies, the two glass layers (1) are completely sealed.