Composite Gasket for Vacuum Insulated Glazing Evacuation
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Solution Overview
Problem
Existing vacuum insulated glazing (VIG) unit manufacturing methods face challenges in achieving a cost-effective and efficient evacuation process due to leaks caused by gaps between the glass pane and evacuation cup, especially at high temperatures, where low melting point gasket materials compromise sealing efficiency.
Innovation Solution
A gasket with a high melting point and low out-of-plane modulus of elasticity is used to provide a compressible and flexible seal between the evacuation cup and glass pane, adapting to surface irregularities and maintaining integrity at high temperatures, ensuring a hermetic seal and efficient vacuum creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If low melting point gasket materials (such as polymer-based gaskets) are used to seal between the glass pane and evacuation cup, then the gasket can adapt to surface irregularities and provide initial sealing, but the gasket will melt at high temperatures and significantly increase the risk of leaks between the sealed surfaces
Solution Approach 1:
The gasket is constructed as a composite structure with a porous core material (such as ceramic foam or sintered metal) providing high temperature stability and a flexible outer layer (such as polymer or rubber) providing adaptability to surface irregularities. This composite structure combines the advantages of both materials while mitigating their individual disadvantages.
Solution Approach 2:
The gasket incorporates a flexible outer shell or film layer that can deform and conform to the irregular surfaces of the glass pane and evacuation cup, ensuring intimate contact and effective sealing even when surfaces are not perfectly flat.
2Productivity
If high temperatures are applied during evacuation to release and evacuate impurities and contaminants from the interior of the VIG unit, then the evacuation quality is improved, but low melting point gasket materials will melt and compromise the sealing efficiency
Solution Approach 1:
The high-temperature stable porous core material (ceramic foam or sintered metal) allows the gasket to withstand the high temperatures required for effective evacuation and thermal cleaning, while the flexible outer layer maintains sealing contact. This enables the system to operate at high temperatures without gasket failure.
Solution Approach 2:
The gasket material's thermal stability parameter is changed by selecting materials with high melting points (ceramics, metals) or by using composite structures that maintain structural integrity at elevated temperatures, allowing the evacuation process to proceed at temperatures sufficient to release and remove contaminants.
3Ease of manufacture
If small gaps exist between the glass pane and evacuation cup, then assembly is easier, but gas can leak sideways across the sealing surfaces resulting in inefficient evacuation
Solution Approach 1:
The flexible outer layer of the gasket can deform to fill and seal small gaps and irregularities between the glass pane and evacuation cup, preventing gas leakage pathways while still allowing for ease of assembly. The flexibility accommodates minor misalignments and surface variations.
Solution Approach 2:
The gasket provides enhanced sealing properties specifically at the critical sealing interface between the glass pane and evacuation cup, while the bulk of the gasket structure can remain relatively simple. The localized application of flexible material at the sealing surface addresses the leakage issue without complicating the overall assembly.
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
The gasket enables a more efficient and cost-effective evacuation process by preventing leaks and maintaining a high-quality vacuum within the VIG unit, even at elevated temperatures, thereby improving the manufacturing efficiency and quality of the VIG units.
Implementation Method 1
is compressible between the evacuation cup and outer surface of the first pane with an out of plane module of elasticity below 50 GPa
Implementation Method 2
Large height variations of the surfaces to be sealed may be filled by the soft gasket material
Implementation Method 3
the high melting point of the gasket material makes it stable across a large temperature range and particularly suitable for the VIG unit manufacture process, comprising high temperatures and large temperature variations
Data Source
AI summary
The invention relates to a gasket for evacuation a void in a vacuum insulated glazing unit, a method for producing a vacuum insulated glazing unit, a gasket for use in the production of a vacuum insulated glazing unit and apparatus comprising an evacuation cup and a gasket. The present invention furthermore relates to the use of a gasket. The gasket is adapted for being positioned between the outer surface of the first pane and an evacuation cup, the evacuation cup comprising, a first cavity with a first cavity opening, an exhaust opening for evacuating the void via the first cavity opening, an evacuation cup body and one or more contact surfaces wherein the gasket is adapted to provide an air tight seal between the evacuation cup and the first glass pane during evacuation of the void, wherein the gasket comprises a gasket material which constitutes the majority of the gasket, is compressible between the evacuation cup and outer surface of the first pane with an out of plane module of elasticity below 50 GPa, such as below 30 GPa, such as below 25 GPa and has a melting temperature above 400 degrees Celsius.