Induction Welding Path Control for Vacuum Insulated Glass Corners
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional induction-heating welding methods for vacuum insulated glass result in over-burning of metal layers at corner regions, reducing bonding strength and affecting the reliability and service life of the glass.
Innovation Solution
The high-frequency induction welding head's movement route is adjusted to deviate from the centerline of the metal layers in corner regions, reducing induction power and preventing overheating by altering the relative position and shape of the metal layers, such as offsetting the welding head's center or changing the metal layer edges to arc-shaped.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the high-frequency induction welding head moves along the centerline of the metal layer at uniform speed, then the welding efficiency is high and the solder is properly heated, but the metal layer at corner regions experiences over-burning and reduced bonding strength
Solution Approach 1:
The patent applies dynamics by making the movement speed of the induction welding head variable rather than uniform. The control system adjusts the moving speed dynamically based on the position: faster at straight sections and slower at corner regions. This resolves the contradiction by maintaining high overall efficiency while preventing over-burning at corners through localized speed reduction.
Solution Approach 2:
The patent changes the motion parameter (speed) of the welding head according to position. By modifying the speed parameter dynamically during the welding process, the system achieves proper heating distribution - sufficient heating at straight sections and controlled heating at corner regions - thereby resolving the contradiction between efficiency and reliability.
2Speed
If the induction heating power is increased to ensure proper solder heating, then the welding speed can be maintained, but the metal layer at corner regions overheats and fuses into the solder, reducing welding strength
Solution Approach 1:
The patent applies local quality by creating different heating conditions for different regions. The corner regions receive reduced heating intensity (through slower movement) compared to straight sections. This localized adjustment prevents overheating at corners while maintaining efficient heating at straight sections, resolving the contradiction between welding speed and temperature control.
Solution Approach 2:
The system dynamically adjusts the effective heating power by varying the dwelling time at different positions. Although the induction coil output power remains constant, the actual energy input to the metal layer is controlled dynamically through speed variation, achieving proper temperature distribution without reducing overall welding speed.
3Temperature
If the induction welding head dwells longer at corner regions to ensure proper heating, then the solder melts adequately, but the metal layer overheats and loses bonding strength
Solution Approach 1:
The patent changes the time parameter dynamically based on position. Instead of uniform dwelling time, the system implements position-dependent timing: shorter dwell at straight sections and optimized dwell at corner regions. This resolves the contradiction by providing sufficient heating time for solder melting while preventing excessive heating that would damage the metal layer's bonding strength.
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 approach enhances the sealing performance, increases product qualification rates, and prolongs the service life of vacuum insulated glass by preventing over-burning and maintaining bonding strength.
Implementation Method 1
a brazing solder can be heated by the high-frequency induction heating
Implementation Method 2
a high-frequency induction welding head is formed by coiling a high-frequency induction coil
Implementation Method 3
a brazing solder can be heated by the high-frequency induction heating
Data Source
AI summary
An induction-heating welding method for vacuum insulated glass comprising upper and lower glass substrates is disclosed. Metal layers are prepared in regions to be sealed for the upper and lower glass substrates. A continuous solder is distributed on the metal layer in the lower glass substrate's region to be sealed. The upper and lower glass substrates are superposed. During welding, a high-frequency induction welding head's center moves forward along a centerline of a width of the metal layers; during induction heating of the metal layers in a corner region, a relative position between a movement route of the high-frequency induction welding head's center and the centerline of the width of the metal layers is changed, so that the movement route deviates from the centerline of the width of the metal layers, and thus reducing induction power and avoiding overheating of the metal layers in the corner region.