Laser-Activated Getter for Vacuum Insulated Glass
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Solution Overview
Problem
Vacuum insulated glass (VIG) window units face challenges in effectively activating getters during the pump-out process, particularly for non-evaporable getter materials which require higher activation temperatures, leading to inefficiencies and extended processing times.
Innovation Solution
Activating getters during or at the end of the evacuation process by directing a laser beam through a pump-out tube to heat the getter, overlapping with the evacuation process to reduce energy and time requirements, and using techniques like localized microwave or RF-inductive heating to achieve the necessary activation temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If getters are activated using conventional heating methods during the pump-out process, then the activation temperature can be achieved, but the processing time is extended and energy consumption increases
Solution Approach 1:
The patent replaces conventional thermal conduction heating with microwave radiation heating to activate getters. The microwave heating system uses electromagnetic fields to directly heat the getter material, achieving the required activation temperature much faster than conventional heating methods, thereby reducing processing time while maintaining effective getter activation
Solution Approach 2:
The patent changes the heating parameter from thermal conduction to microwave radiation frequency. By using microwave radiation at specific frequencies, the getter material absorbs electromagnetic energy directly, converting it to thermal energy rapidly. This parameter change enables achieving activation temperature in a fraction of the time required by conventional heating methods
2Temperature
If conventional heating methods are used to activate getters, then the activation process can be completed, but energy consumption increases
Solution Approach 1:
The patent substitutes microwave radiation heating for conventional thermal conduction heating. Microwave heating transfers energy directly to the getter material through electromagnetic field interaction, achieving higher heating efficiency and reduced energy loss to the surrounding environment, thereby lowering overall energy consumption while achieving the required activation temperature
Solution Approach 2:
The patent implements continuous microwave heating during the pump-out process, allowing getter activation to occur concurrently with vacuum evacuation. This continuous action eliminates the need for separate heating and pumping stages, reducing total energy consumption by avoiding repeated heating cycles and maintaining constant useful action throughout the manufacturing process
3Quantity of substance
If the pump-out process is completed before getter activation, then the cavity is fully evacuated, but additional time and energy are required for separate getter activation
Solution Approach 1:
The patent merges the pump-out process and getter activation into a single integrated operation. Microwave radiation heating is applied during the vacuum evacuation process, allowing the getter to be activated while the cavity is being pumped down. This merging of operations eliminates the need for separate activation and pumping stages, increasing production throughput while ensuring complete evacuation and effective impurity binding
Solution Approach 2:
The patent applies preliminary microwave heating to activate the getter before the pump-out process is fully complete. By initiating getter activation early in the evacuation process, the system prepares the getter to immediately begin binding residual impurities as they are pumped out, maximizing the efficiency of both the evacuation and gettering processes simultaneously
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 reduces the time and energy needed for getter activation, increases the throughput of VIG window unit production, and ensures effective binding of residual impurities, enhancing the overall efficiency of the fabrication process.
Implementation Method 1
directing a laser beam through a pump-out tube to heat the getter
Implementation Method 2
using techniques like localized microwave or RF-inductive heating to achieve the necessary activation temperatures
Implementation Method 3
using techniques like localized microwave or RF-inductive heating to achieve the necessary activation temperatures
Implementation Method 4
The getter is of or includes a mixture of metals that can react with gas(es) to hold gas(es) impurities to the gettering surface and/or dissolve such gas(es)
Data Source
AI summary
Methods of making vacuum insulated glass (VIG) window units are provided, including activating getters in a process of making VIG window units. In certain example embodiments, at least one getter is activated during and/or at the end of a pump-out/evacuation process in which the cavity between the substrates is evacuated. In certain example embodiments, the getter(s) may be activated (e.g., by at least a laser beam that is directed through a pump-out tube) during and/or at the end of the evacuation process in which the cavity between the substrates is evacuated to a low pressure that is below atmospheric pressure.