Glass Panel Unit Manufacturing with Segmented Frit Seal
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Solution Overview
Problem
Existing methods for manufacturing glass panel units face challenges in preventing the exhaust port or air passage from being closed during the gas exhaustion process, which can lead to incomplete evacuation and reduced thermal insulation performance.
Innovation Solution
A method involving a glue arrangement step, assembly forming, first melting to bond the glass panels with hot glue, evacuation to reduce pressure, and a second melting step to seal the exhaust port, with controlled temperature steps to prevent deformation of the hot glue and ensure a hermetically sealed evacuated space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the frit seal is heated to bond the glass panes together, then the bonding strength is improved, but the discontinuous portion may close and the exhaust port may be blocked
Solution Approach 1:
The sealing structure is divided into two distinct parts: a continuous frit seal for bonding and a separate discontinuous sealing member for exhaust control. This segmentation allows the exhaust port to remain open during bonding while enabling controlled sealing afterward.
Solution Approach 2:
The discontinuous sealing member is positioned in advance to cover the exhaust port only after the bonding process is complete. This preliminary arrangement ensures the exhaust port remains accessible during heating and bonding operations.
2Productivity
If the gas exhaustion is performed quickly, then the productivity is improved, but the risk of exhaust port closure increases
Solution Approach 1:
The discontinuous sealing member is pre-positioned to cover the exhaust port after bonding is complete, allowing immediate sealing without requiring slow, staged exhaustion processes.
Solution Approach 2:
The sealing mechanism transitions from an open state during bonding to a closed state after bonding by activating the discontinuous sealing member, allowing rapid exhaustion without risk of closure during the process.
3Reliability
If the frit seal is made continuous for hermetic bonding, then the sealing performance is improved, but the exhaust function is compromised
Solution Approach 1:
The sealing system is segmented into a continuous frit seal for hermetic bonding and a discontinuous sealing member for exhaust control. This allows both hermetic sealing and exhaust functionality to coexist without conflict.
Solution Approach 2:
The sealing member transitions from an open configuration during bonding to a closed configuration after bonding, dynamically adapting the sealing state to match the process requirements at different stages.
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 method effectively reduces the chances of the exhaust port being closed, ensuring a complete evacuation and maintaining the integrity of the evacuated space, thereby enhancing the thermal insulation performance 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
bonding the first panel and the second panel together with the hot glue thus melted
Implementation Method 3
raising a temperature of the assembly to a temperature equal to or higher than a softening point of the hot glue
Implementation Method 4
reducing pressure in the internal space by evacuation that involves exhausting a gas from the internal space via the exhaust port
Implementation Method 5
creating a hermetically sealed evacuated space by heating the assembly and thereby melting the hot glue while maintaining a reduced pressure in the internal space to close the exhaust port
Data Source
AI summary
A method for manufacturing a glass panel unit includes a glue arrangement step, an assembly forming step, a first melting step, an evacuation step, and a second melting step. The first melting step includes melting a hot glue, bonding a first and second panel with the glue, and forming an internal space. The first melting step includes a first temperature raising step, a first temperature maintaining step including maintaining the temperature of the assembly at a temperature equal to or higher than a softening point of the hot glue, and a first temperature lowering step, which are performed in this order. The first temperature lowering step includes: an anterior temperature lowering step including lowering the temperature of the assembly; a middle temperature maintaining step including maintaining the temperature of the assembly; and a posterior temperature lowering step including lowering the temperature of the assembly, which are performed in this order.