Glass Panel Unit Vacuum Sealing via Frame Deformation
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Solution Overview
Problem
The existing manufacturing methods for glass panel units require the use of a large-scale sealing evacuation furnace, making the process complex and inefficient.
Innovation Solution
A manufacturing method that involves a preassembled component with a frame member, gas adsorbent, and spacers, where the component is housed in a chamber with a thermally conductive pressing part to achieve a vacuum state and seal the exhaust port without the need for a large-scale furnace, using a chamber device with a deformable bag and a heater to deform the frame member and close the exhaust port.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large-scale sealing evacuation furnace is used to achieve vacuum state and seal the exhaust port, then the vacuum sealing can be achieved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The manufacturing process is divided into two separate stages: first, the preassembled component is evacuated in a simple chamber to achieve vacuum state; second, the frame member is heated separately to deform and seal the exhaust port. This segmentation eliminates the need for a complex large-scale furnace that must simultaneously perform both evacuation and sealing at high temperature.
Solution Approach 2:
The exhaust port is sealed by deforming the frame member through heating after the vacuum state has already been achieved. This preliminary evacuation followed by separate sealing action allows the use of a simpler chamber for the evacuation process, reducing overall device complexity while maintaining sealing quality.
2Reliability
If a large-scale sealing evacuation furnace is used, then vacuum sealing can be achieved, but energy consumption increases
Solution Approach 1:
The process separates evacuation and sealing operations into distinct stages performed in a single chamber. The chamber is evacuated to create vacuum, then the frame member is heated only locally to deform and seal the exhaust port. This avoids the continuous high-temperature operation required by traditional furnaces, significantly reducing energy consumption.
Solution Approach 2:
The heating process is applied briefly and locally only when needed to deform the frame member for sealing, rather than maintaining continuous high temperature. This rushed-through heating approach minimizes energy input while achieving the necessary sealing effect.
3Reliability
If the frame member is heated to deform and seal the exhaust port, then the vacuum state is maintained, but the chamber may deform or break under high temperature
Solution Approach 1:
The heating function is extracted from the chamber structure itself and applied externally or locally to the frame member only. The chamber acts solely as an evacuation vessel, while the frame member serves as the heating and sealing component. This separation protects the chamber from high-temperature damage.
Solution Approach 2:
The frame member acts as an intermediary that absorbs the thermal stress and deformation required for sealing, protecting the chamber structure from direct exposure to high temperatures. The frame member deforms to seal the exhaust port while the chamber remains at lower temperatures, maintaining its structural integrity.
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 simplifies the manufacturing process, reduces the need for specialized equipment, saves energy, and allows for the production of glass panel units with a high degree of vacuum without deforming or breaking the chamber, making it reusable.
Implementation Method 1
evacuating the chamber (81) through an air passage (86) to achieve a reduced pressure state in the chamber (81)
Implementation Method 2
heating the frame member (410) of the preassembled component (100) stored in the chamber (81) with a heater (88) to deform the frame member (410) to close the exhaust port (700)
Implementation Method 3
a part of the chamber (81) serving as a pressing part (82) which is thermally conductive
Data Source
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AI summary
An object of the present invention is to provide a manufacturing method of a glass panel unit which is simply performable. A manufacturing method of a glass panel unit of the present invention includes housing a preassembled component in a chamber and evacuating the chamber to achieve a reduced pressure state. The preassembled component includes a first glass panel, a second glass panel, and a frame member disposed between the first glass panel and the second glass panel to hermetically bond the first glass panel to the second glass panel. The frame member has an exhaust port communicating with an inside space and an outside space. The chamber has a part as a thermally conductive pressing part which is movable to press the first glass panel and the second glass panel in a direction in which the first glass panel and the second glass panel approach each other. The manufacturing method includes heating the frame member by a heater to deform the frame member to close the exhaust port.