Laser-Fired Vacuum Insulated Panel Seals to Prevent Glass De-Tempering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional vacuum insulated glass panels face issues such as significant de-tempering of glass substrates, high manufacturing costs, and structural integrity problems due to thermal stress gradients, leading to safety concerns and increased breakage rates.
Innovation Solution
A method involving laser heating to transform TeO4>TeO3 and V2O5>VO2 in the seal material, forming a hermetic edge seal that maintains compressive and tensile stresses in the glass substrates, reduces thermal stress gradients, and improves durability and hermeticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermal processing is used to form the seal, then the seal material can be fired and sintered, but significant de-tempering of glass substrates occurs and thermal stress gradients cause structural integrity problems
Solution Approach 1:
The patent replaces conventional thermal field processing with laser beam processing. The laser beam provides localized, controlled energy input that fires and sinters the seal material without creating the widespread thermal gradients that cause de-tempering. This substitution of the processing mechanism eliminates the thermal stress gradient problem while achieving the required seal hermeticity.
Solution Approach 2:
The laser beam processing method applies heat locally only to the seal material region, rather than heating the entire glass panel uniformly. This localized processing allows the seal to be fired and sintered while the rest of the glass substrate maintains its tempering stress integrity, preventing de-tempering and structural problems.
2Reliability
If conventional heating methods are used to fire seal material, then sealing can be achieved, but manufacturing costs increase and production efficiency decreases
Solution Approach 1:
The patent replaces conventional thermal field processing with laser beam processing. The laser method provides more precise control over the firing process, reducing energy waste and processing time. This substitution improves manufacturing efficiency and reduces costs while maintaining seal durability through controlled, localized heating that achieves complete sintering faster and more reliably.
3Reliability
If uniform heating is applied to fire seal material, then the seal can be formed, but thermal stress gradients lead to increased breakage rates
Solution Approach 1:
The laser beam processing method applies heat locally only to the seal material region, rather than heating the entire glass panel uniformly. This localized processing allows the seal to be fired and sintered while the rest of the glass substrate maintains its tempering stress integrity, preventing de-tempering and structural problems.
Solution Approach 2:
The patent replaces conventional thermal field processing with laser beam processing. The laser beam provides localized, controlled energy input that fires and sinters the seal material without creating the widespread thermal gradients that cause de-tempering. This substitution of the processing mechanism eliminates the thermal stress gradient problem while achieving the required seal 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 method ensures the vacuum insulating panels maintain required compressive and tensile stresses, enhance durability, and reduce de-tempering, while being cost-effective and efficient in production.
Implementation Method 1
laser heating, using a laser beam from a laser, the first seal material for firing and/or sintering the first seal material
Implementation Method 2
improved heating efficiency due to increased absorption in the near-IR
Implementation Method 3
laser heating, using a laser beam from a laser, the first seal material for firing and/or sintering the first seal material to form the first seal layer
Data Source
AI summary
A method of making a vacuum insulating panel including a first substrate, a second substrate, a plurality of spacers provided in a gap between at least the first and second substrates, and a seal provided between at least the first and second substrates, the seal comprising a first seal layer, and optionally second and/or third primer layer(s). The method may include at least one of: (i) laser heating, using a laser beam from a laser, the first seal material for firing and/or sintering the first seal material to form the first seal layer, in a manner that causes TeO4>TeO3 in the first seal material to transform into TeO3>TeO4 due to said laser heating, whereby an amount of TeO4 decreases and an amount of TeO3 increases due to said laser heating, and/or (ii) laser heating in a manner that causes V2O5>VO2 in the first seal material to transform into VO2>V2O5 due to said laser heating whereby an amount of VO2 increases and an amount of V2O5 decreases due to said laser heating, so that after said laser heating the first seal layer comprises more VO2 than V2O5 by wt. %.