Glass Panel Unit Staged Evacuation for Pillar Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing multi-pane glazing units face challenges in preventing displacement of pillars during the evacuation of gas from the internal space, leading to potential misalignment and structural issues.
Innovation Solution
A method involving a sequential evacuation process with controlled channel areas and valve operations, combined with a heating schedule to minimize pillar displacement, is employed to create a hermetically sealed evacuated space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If spacers are arranged on the first panel or the second panel to be hermetically bonded together, then the panels can be bonded together with the sealant, but the spacers are likely to be displaced when gas is exhausted from the internal space
Solution Approach 1:
The patent applies preliminary action by arranging the spacers on a separate support surface before bonding the panels together. This allows the spacers to be positioned accurately in advance without being subjected to the bonding process and subsequent gas exhaustion that would cause displacement. The spacers are pre-positioned on the support surface, then the panels are bonded around them, ensuring their positions remain stable throughout the manufacturing process.
2Productivity
If high suction power is used to exhaust gas from the internal space, then the evacuation efficiency is improved, but the pillars are more likely to be displaced
Solution Approach 1:
The patent applies segmentation by dividing the evacuation process into multiple stages with progressively increasing suction power. Instead of using high suction power from the beginning, the process starts with lower suction power to prevent pillar displacement, then gradually increases to higher levels as the pressure differential decreases and pillars become more stable. This segmented approach maintains both evacuation efficiency and manufacturing precision.
Solution Approach 2:
The patent implements periodic action through a multi-stage evacuation process where suction power is adjusted in periodic increments. The evacuation proceeds through several phases, each with controlled suction levels, allowing the system to adapt to changing conditions and prevent pillar displacement while maintaining overall evacuation efficiency.
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 method effectively reduces the chances of pillar displacement and ensures a stable, hermetically sealed evacuated space is formed, enhancing the structural integrity of the glass panel unit.
Implementation Method 1
heating the assembly to melt the hot glue, bonding the first panel and the second panel together with the hot glue thus melted
Implementation Method 2
reducing pressure in the internal space by evacuation that involves exhausting, with predetermined suction power, a gas from the internal space
Data Source
AI summary
A method for manufacturing a glass panel unit includes a glue arrangement step, a pillar placement step, an assembly forming step, a bonding step, an evacuation step, and a sealing step. The evacuation step reduces pressure in an internal space by exhausting, with predetermined suction power, a gas from the internal space via a valve and an exhaust port. The valve includes a first valve allowing the gas to flow through a first channel area and a second valve allowing the gas to flow through a second channel area larger than the first channel area. The evacuation step includes a first evacuation step to be performed first and a second evacuation step to be performed next. In the first evacuation step, the first valve is opened and the second valve is closed. In the second evacuation step, the first valve is closed and the second valve is opened.