Vacuum Insulated Panel Edge Seal With Graded CTE Layers
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Solution Overview
Problem
Conventional vacuum insulated glass panels face issues such as significant de-tempering of glass substrates, high manufacturing costs, and durability problems due to thermal stress and hermeticity issues, which hinder their commercial viability and compliance with safety codes.
Innovation Solution
A vacuum insulating panel design with a multi-layer edge seal structure, utilizing a main seal layer and primer layers with controlled thermal expansion coefficients, combined with laser-based selective heating to minimize thermal stress and ensure hermeticity, durability, and compliance with safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing methods are used to create hermetic seals in vacuum insulated panels, then the panels can be manufactured, but significant de-tempering of glass substrates occurs and durability problems arise due to thermal stress
Solution Approach 1:
The patent applies parameter changes by carefully selecting and controlling the coefficient of thermal expansion (CTE) of seal layers to match the glass substrates. The first seal layer has a CTE of 7.0-7.9×10^-6 mm/(mm*deg·C.), the second seal layer has a CTE of 8.0-8.8×10^-6 mm/(mm*deg·C.), and the third seal layer has a CTE of 8.0-8.8×10^-6 mm/(mm*deg·C.), creating a gradient that minimizes thermal stress and prevents de-tempering while maintaining hermeticity.
Solution Approach 2:
The patent uses composite materials by creating a multi-layer seal structure with different materials having different CTE properties. The gradient CTE design (first seal layer: 7.0-7.9×10^-6, second seal layer: 8.0-8.8×10^-6, third seal layer: 8.0-8.8×10^-6 mm/(mm*deg·C.)) creates a composite structure that bridges the thermal expansion mismatch between the sealant and glass substrates, reducing thermal stress gradients and improving durability.
2Ease of manufacture
If conventional sealing structures are used, then manufacturing can proceed, but thermal stress gradients cause durability problems and compliance issues with safety codes
Solution Approach 1:
The patent changes the CTE parameters of the seal layers to create a gradient structure that naturally reduces thermal stress. The specific CTE ranges (first seal layer: 7.0-7.9×10^-6, second seal layer: 8.0-8.8×10^-6, third seal layer: 8.0-8.8×10^-6 mm/(mm*deg·C.)) are selected to ensure compatibility with glass substrates (CTE: 8.7-9.3×10^-6 mm/(mm*deg·C.)) while maintaining manufacturing feasibility.
Solution Approach 2:
The multi-layer seal structure acts as an intermediary between the glass substrates and the sealing function. The gradient CTE design creates intermediate layers that progressively transition between different thermal expansion properties, mediating the thermal stress and preventing direct stress concentration that would cause durability problems.
3Reliability
If high thermal stress is present in the sealing process, then hermetic seals can be formed, but significant thermal stress gradients reduce durability
Solution Approach 1:
The patent changes the thermal expansion parameters of the seal layers to create a gradient that accommodates thermal stress during sealing. The CTE values (first seal layer: 7.0-7.9×10^-6, second seal layer: 8.0-8.8×10^-6, third seal layer: 8.0-8.8×10^-6 mm/(mm*deg·C.)) are specifically selected to reduce thermal stress gradients while maintaining sufficient thermal stress for hermetic sealing.
Solution Approach 2:
The patent employs composite materials with a gradient CTE structure where each layer has different thermal expansion properties. This composite design allows the seal to withstand thermal stress during formation while distributing thermal stress gradients across multiple layers, thereby improving long-term durability without compromising hermeticity.
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 solution maintains high compressive and tensile stresses in glass substrates, reduces thermal stress gradients, and improves hermeticity and durability, enabling cost-effective production of vacuum insulated panels that meet safety requirements.
Implementation Method 1
wherein a coefficient of thermal expansion (CTE) of the second seal layer may be greater than a CTE of the first seal layer, a CTE of the third seal layer may be greater than the CTE of the first seal layer, the CTE of the second seal layer may be less than a CTE of the first glass substrate, and the CTE of the third seal layer may be less than a CTE of the second glass substrate
Implementation Method 2
combined with laser-based selective heating to minimize thermal stress and ensure hermeticity, durability, and compliance with safety standards
Implementation Method 3
The gap between the substrates may be at a pressure less than atmospheric pressure to provide insulating properties. Providing a vacuum in the space between the substrates reduces conduction and convection heat transport
Implementation Method 4
Providing a vacuum in the space between the substrates reduces conduction and convection heat transport
Data Source
AI summary
A vacuum insulating panel includes first and second substrates (e.g., glass substrates), a hermetic edge seal, a pump-out port, and spacers sandwiched between at least the two substrates. The gap between the substrates may be at a pressure less than atmospheric pressure to provide insulating properties. The vacuum insulating panel may include a multi-layer edge seal structure with coefficients of thermal expansion (CTEs) of layers of the seal structure optimized for CTE grading.