Glass Panel Unit Manufacturing Without Clips
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Solution Overview
Problem
In the manufacturing of multi-pane glazing units, panels with warpage pose challenges for the sealant to contact both panels uniformly, requiring clips to ensure no gaps are left between the panels and the sealant during hermetic bonding.
Innovation Solution
A method involving a glue arrangement step, pillar forming, assembly forming, bonding, evacuation, and sealing steps, where hot glue is applied to one panel, pillars are placed, and the assembly is heated to bond the panels with an internal space evacuated, eliminating the need for clips by allowing the panels to self-adjust and eliminate warpage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If clips are used to tightly hold the first panel and second panel together, then no gap is left between the panels and sealant, but the device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts and removes the clip component from the manufacturing process. By using a support table with a table top that has a table top surface capable of supporting the first panel, and utilizing the warpage of the first panel itself to apply pressure, the patent eliminates the need for separate clips while still achieving tight bonding between panels and sealant.
Solution Approach 2:
The invention makes the first panel serve dual functions: it is both the panel to be bonded and the pressing tool. The warpage of the first panel is utilized to automatically apply pressure during bonding, eliminating the need for external clips. The support table provides the platform, and the panel's own deformation does the pressing work.
2Reliability
If clips are used to hold panels together during bonding, then hermetic sealing is achieved, but manufacturing cost increases
Solution Approach 1:
The invention removes the clip component from the manufacturing process. The support table with its table top surface replaces the clip's holding function, while the warpage of the first panel provides the pressing force, achieving hermetic sealing without additional parts or cost.
Solution Approach 2:
The invention replaces expensive, complex clip mechanisms with a simple, inexpensive support table structure. The table top is a basic supporting surface that can be part of the existing bonding equipment, significantly reducing manufacturing cost while maintaining sealing reliability.
3Manufacturing precision
If the first panel with warpage is used without support, then the warpage causes bonding issues, but adding support structures increases complexity
Solution Approach 1:
The invention extracts the complex support structure and replaces it with a simple support table having a table top surface. This minimal support structure is sufficient to hold the first panel while allowing the warpage to be utilized beneficially for applying pressure during bonding.
Solution Approach 2:
The support table acts as an intermediary between the first panel and the bonding process. The table top surface provides the necessary support platform, while the panel's warpage serves as the intermediary mechanism for applying pressure, eliminating the need for complex active support structures.
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 ensures a hermetically sealed evacuated space without gaps between the panels and the hot glue, reducing manufacturing costs and simplifying the process by allowing the panels to self-adjust and eliminate warpage during bonding.
Implementation Method 1
heating the assembly with the first panel arranged to form an upper part of the assembly and the second panel arranged to form a lower part of the assembly
Implementation Method 2
the hot glue that has melted by heating the assembly
Implementation Method 3
The evacuation step includes reducing pressure in the internal space by evacuation that involves exhausting a gas from the internal space
Data Source
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AI summary
Provided is a method for manufacturing a glass panel unit without using a clip to tightly hold a first panel and a second panel together. A glass panel unit (10) manufacturing method includes a glue arrangement step, a pillar forming step, an assembly forming step, a bonding step, an evacuation step, and a sealing step. The glue arrangement step includes arranging a hot glue (including a frame member (410) and a partition (420)) on either a first panel (20) having a predetermined degree of warpage or a second panel (30). The pillar forming step includes placing pillars (70) on either the first panel or the second panel. The assembly forming step includes forming an assembly (100). The bonding step includes heating the assembly with the first panel arranged to form an upper part of the assembly and the second panel arranged to form a lower part of the assembly to bond the first panel and the second panel together. The evacuation step includes reducing pressure in an internal space (500) by evacuation. The sealing step includes creating a hermetically sealed evacuated space (50) by closing an exhaust port (700).