Glass Panel Unit Manufacturing Method for Binder Removal and Vacuum Integrity

Solution Overview

Problem

The existing glass panel unit manufacturing methods face challenges in completely removing the binder from the glass adhesive, which can reduce adhesive strength and affect the vacuum space integrity, leading to potential separation of panels and discoloration of the sealing member.

Innovation Solution

A method involving the use of a glass adhesive with a low step part design and pre-calcining, where the adhesive is heated to remove the binder and form a vacuum space, with specific temperature control to ensure complete binder removal and integration of glass particles, while maintaining manufacturing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If glass adhesive containing binder is used for bonding panels, then ease of application is improved, but complete binder removal is difficult leading to reduced adhesive strength and vacuum space integrity

Engineering Contradiction:

Improveease of applicationVSAvoidadhesive strength

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-calcining the glass adhesive before bonding the panels. This preliminary heating treatment removes the binder in advance, allowing the glass particles to be activated and integrated into the bonding layer before the actual bonding process, thus ensuring complete binder removal while maintaining ease of application

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes by controlling the heating temperature and duration during the bonding process. By adjusting these parameters, the glass particles are activated and melted to form a strong bonding layer, while the binder is completely removed through controlled thermal decomposition

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If binder is not completely removed from glass adhesive, then manufacturing complexity is reduced, but adhesive strength and vacuum space integrity are compromised

Engineering Contradiction:

Improvemanufacturing process complexityVSAvoidvacuum space integrity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-calcining the glass adhesive before bonding the panels. This preliminary heating treatment removes the binder in advance, allowing the glass particles to be activated and integrated into the bonding layer before the actual bonding process, thus ensuring complete binder removal while maintaining ease of application

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes by controlling the heating temperature and duration during the bonding process. By adjusting these parameters, the glass particles are activated and melted to form a strong bonding layer, while the binder is completely removed through controlled thermal decomposition

Inventive Principle:

Principle #35Parameter changes

3Strength

If heating is applied to remove binder from glass adhesive, then adhesive strength is improved, but energy consumption increases

Engineering Contradiction:

Improveadhesive strengthVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The patent applies preliminary action by pre-calcining the glass adhesive before bonding the panels. This preliminary heating treatment removes the binder in advance, allowing the glass particles to be activated and integrated into the bonding layer before the actual bonding process, thus ensuring complete binder removal while maintaining ease of application

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes by controlling the heating temperature and duration during the bonding process. By adjusting these parameters, the glass particles are activated and melted to form a strong bonding layer, while the binder is completely removed through controlled thermal decomposition

Inventive Principle:

Principle #35Parameter changes

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 effectively removes the binder, enhances adhesive strength between panels, and stabilizes the vacuum space, improving the thermal insulation properties of the glass panel units.

Implementation Method 1

heating the glass adhesive enables particles of the glass powder to be melted and integrated with each other

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

heating the glass adhesive enables particles of the glass powder to be melted and integrated with each other while the binder is removed

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Data Source

PatentUS10882784B2Glass panel unit manufacturing method and glass window manufacturing method

Publication Date: 2021.01.05 PANASONIC HOUSING SOLUTIONS CO LTD

AI summary

An object of the invention is to provide a glass panel unit manufacturing method and a glass window manufacturing method which enable a binder to be effectively removed from a glass adhesive, provide high adhesive strength between panels, and enable a vacuum space to be stably formed. A method for manufacturing a glass panel unit includes: disposing a glass adhesive to have one part as a low step part thinner than the other part of the glass adhesive; disposing a first substrate including at least a first glass substrate and a second substrate including at least a second glass substrate to face each other; and heating glass composite to form an inner space; reducing the pressure of the inner space; and forming a vacuum space from the inner space. The glass adhesive includes glass powder and a binder.