Ceramic Heater Evacuation Head for VIG Sealing
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Solution Overview
Problem
Vacuum insulating glazing (VIG) unit production faces challenges with achieving a better contact seal between the evacuation head and glass pane, enhanced evacuation tube seal, and maintaining tempered glass integrity during the manufacturing process, particularly due to issues with temperature distribution and the limitations of existing heater technologies.
Innovation Solution
The use of a ceramic heating element within the evacuation head, which is adaptable and capable of multiple temperature settings, combined with a reduced contact width for improved thermal conduction and hermetic sealing, ensures a more uniform temperature distribution and effective sealing of the evacuation tube tip, while maintaining the integrity of tempered glass by keeping temperatures below annealing levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional heater is used in the evacuation head, then the evacuation tube tip can be sealed, but the temperature distribution is non-uniform causing glass warping and compromising tempered glass integrity
Solution Approach 1:
The patent applies parameter changes by switching from a traditional heater to a ceramic heating element, which fundamentally changes the heating characteristics. The ceramic heater provides superior temperature uniformity and control, transforming the thermal field distribution during evacuation tube tip sealing. This parameter change resolves the contradiction by achieving uniform temperature distribution (improving manufacturing precision) while preventing glass warping and maintaining tempered glass integrity (eliminating harmful factors).
Solution Approach 2:
The ceramic heating element enables localized and controlled heating of the evacuation tube tip area. By concentrating thermal energy precisely where needed (at the tube tip) while maintaining uniform temperature distribution across the heated zone, the system achieves effective sealing without causing thermal stress or warping in surrounding glass areas. This local quality approach resolves the contradiction between achieving sufficient heat for sealing and avoiding harmful temperature variations.
2Reliability
If the evacuation head contact width is reduced, then thermal conduction and hermetic sealing are improved, but the heating effectiveness may be compromised
Solution Approach 1:
The patent employs composite materials by combining the ceramic heating element with the evacuation head structure. The ceramic material provides both excellent thermal conduction for effective heating and compatibility with the hermetic sealing requirements. This composite approach allows the reduced contact width design to maintain both reliability (hermetic sealing) and power (heating effectiveness) simultaneously, as the ceramic heater efficiently transfers heat through the smaller contact area without compromising sealing integrity.
Solution Approach 2:
The introduction of the ceramic heating element changes the thermal and mechanical parameters of the evacuation head system. The ceramic material's specific thermal conductivity, heat capacity, and mechanical properties enable the reduced contact width design to achieve both improved hermetic sealing and maintained heating effectiveness. The parameter changes in the heating system allow the smaller contact area to be more efficient, resolving the apparent contradiction between reduced contact width and heating power.
3Manufacturing precision
If higher temperatures are applied for better tube tip sealing, then sealing quality improves, but tempered glass integrity is compromised due to exceeding annealing temperatures
Solution Approach 1:
The ceramic heating element enables precise temperature control and feedback management during the tube tip sealing process. The system can monitor and adjust the heating temperature in real-time, maintaining it within the optimal range for sealing (sufficiently high for quality seals) while preventing excursions above the glass annealing temperature (protecting tempered glass integrity). This feedback capability resolves the contradiction by allowing high-quality sealing without compromising glass strength.
Solution Approach 2:
The patent applies parameter changes by utilizing the ceramic heater's superior temperature control characteristics. The ceramic heating element can maintain stable, precise temperatures and respond quickly to control inputs, enabling the process to operate at the optimal sealing temperature without exceeding the glass annealing point. This precise parameter control allows achieving high sealing quality while protecting tempered glass integrity, resolving the contradiction between these two requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in enhanced VIG units with improved insulation properties, reduced risk of glass warping, and increased durability of the sealing process, allowing for more efficient energy savings and longer glass lifespan.
Implementation Method 1
the evacuation head has a ceramic heating element; and heating the ceramic heating element and sealing off an evacuation tube tip
Data Source
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AI summary
A vacuum insulated glass (VIG) unit and corresponding evacuation head 8. An evacuation head 8 with a ceramic heating element 9 is presented. And a method to produce a VIG using such evacuation head. The VIG may be tempered glass and the VIG may be evacuated in an oven.