Vacuum Insulated Glass Edge Seal With Short-Duration Laser Sintering
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Solution Overview
Problem
Conventional vacuum insulated glass panels face issues such as significant de-tempering of glass substrates, reduced durability, high manufacturing costs, and difficulties in maintaining vacuum hermeticity due to thermal stress and inefficient sealing processes.
Innovation Solution
The method involves using a multi-layer edge seal structure with a main seal layer and primer layers, where the main seal layer is made of ceramic tellurium oxide-based material and the primer layers are designed to absorb laser energy, allowing for localized laser firing to form a durable and hermetic seal without excessive thermal stress, thereby maintaining compressive and tensile stresses within safe limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sealing processes are used to create hermetic seals in vacuum insulated panels, then sealing is achieved, but significant de-tempering of glass substrates occurs and durability is reduced
Solution Approach 1:
The seal structure is divided into multiple functional layers: a primer layer applied to the glass substrate, and a seal material layer applied over the primer. This segmentation allows each layer to perform its specific function - the primer adheres to glass while the seal material provides hermetic sealing - without requiring the entire seal structure to be heated to high temperatures that would de-temper the glass.
Solution Approach 2:
The patent changes the thermal parameters of the sealing process by using a laser heating method that selectively heats only the seal material to its melting point for a very short duration (no more than 5 seconds), rather than heating the entire assembly to high temperatures for extended periods. This parameter change allows hermetic sealing without significant de-tempering of the glass substrates.
2Reliability
If high temperature heating is used to fire and sinter seal material, then hermetic sealing is achieved, but thermal stress increases and manufacturing complexity increases
Solution Approach 1:
The patent replaces conventional thermal field heating methods (ovens, furnaces) with a laser heating system that uses concentrated optical energy to selectively heat the seal material. This substitution allows precise localized heating without the need for complex thermal management systems, reducing manufacturing process complexity while achieving hermetic sealing.
Solution Approach 2:
The laser heating is applied as a periodic or pulsed action rather than continuous heating, heating the seal material to melting point for no more than 5 seconds. This periodic heating approach achieves sintering and hermetic sealing while minimizing thermal stress and reducing the complexity of thermal control systems.
3Manufacturing precision
If extended laser heating duration is used to ensure complete sealing, then sealing completeness is improved, but de-tempering of glass substrates increases
Solution Approach 1:
The laser heating system provides localized heating specifically to the seal material region, rather than heating the entire panel assembly. This local quality approach ensures complete sealing of the seal material while leaving the glass substrates at temperatures that do not cause significant de-tempering, maintaining both seal completeness and glass strength.
Solution Approach 2:
The patent rushes through the critical heating phase by heating the seal material to melting point for no more than 5 seconds - a very short duration that is sufficient to achieve complete sealing and sintering. This rapid heating approach completes the sealing process before significant heat can conduct to the glass substrates, preventing de-tempering while ensuring seal completeness.
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 results in improved durability, reduced de-tempering, and cost-effective manufacturing of vacuum insulated panels with enhanced sealing properties and compliance with safety standards.
Implementation Method 1
after said pre-heating, laser heating the first seal material in order to fire and/or sinter the first seal material and form the first seal layer, wherein said laser heating may cause at least one of the first seal material and/or the second seal layer to reach a temperature above the melting point (Tm) of the first seal material for no more than about 5 seconds
Implementation Method 2
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 3
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
Implementation Method 5
reducing radiative energy with a low-emissivity (low-E) coating provided on one of the substrates
Data Source
AI summary
A method of making a vacuum insulating panel, where the vacuum insulating panel may include a first glass substrate, a second glass substrate, a plurality of spacers provided in a gap between at least the first and second glass substrates, and a seal provided at least partially between at least the first and second glass substrates, wherein the seal may comprise a first seal layer and/or a second seal layer. The method may include at least one of: providing first seal material for the first seal layer at a location at least partially between at least the first and second glass substrates; pre-heating so as to cause at least one of (a) at least one of the glass substrates, (b) the second seal layer, and/or (c) the first seal material, to reach a pre-heat temperature; after said pre-heating, laser heating the first seal material in order to fire and/or sinter the first seal material and form the first seal layer in a manner so that the first seal layer may have a density of from about 2.8-4.0 g/cm3, wherein said laser heating may cause at least one of the first seal material and/or the second seal layer to reach a temperature above the melting point (Tm) of the first seal material for no more than about 5 seconds; and after forming the first seal layer, evacuating the gap to a pressure less than atmospheric pressure.