Continuous Vacuum Glass Processing with Segmented Chambers
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Solution Overview
Problem
Current vacuum glass manufacturing methods face challenges in achieving continuous production of high vacuum degrees due to the narrow space between glass plates, leading to prolonged processing times and difficulties in obtaining high vacuum levels.
Innovation Solution
A device comprising a loading table, front-end and back-end auxiliary vacuum chambers, and a main vacuum chamber, with an electric control system, glass plate conveying mechanisms, and sealing devices, allowing for sequential processing and independent vacuum control to maintain high vacuum levels throughout the production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the distance between adjacent glass plates is reduced to minimize space, then the vacuum chamber size is reduced, but the vacuum extraction time is prolonged and high vacuum degree is difficult to obtain
Solution Approach 1:
The vacuum chamber is segmented into multiple independent vacuum chambers arranged in series along the glass plate conveying path. Each chamber can be vacuumized independently and simultaneously, allowing the total vacuum extraction task to be divided into parallel sub-tasks. This segmentation enables high vacuum degree to be achieved without prolonging the overall extraction time, as multiple chambers work concurrently rather than sequentially.
Solution Approach 2:
The invention transitions from a single-chamber sequential vacuum extraction to a multi-chamber parallel vacuum extraction system. By adding the dimension of spatial distribution of multiple chambers, the system achieves vacuum extraction in parallel across different spatial locations, effectively converting a time-consuming sequential process into a simultaneous parallel process, thus reducing total extraction time while maintaining high vacuum degree.
2Device complexity
If traditional vacuum glass manufacturing methods are used, then the structure is simple, but continuous production cannot be realized
Solution Approach 1:
The manufacturing system is designed with multiple vacuum chambers and conveying mechanisms that operate continuously in sequence. Glass plates are conveyed through each chamber in an unbroken flow, with each chamber performing vacuum extraction, sealing, or quality control functions without interrupting the production stream. This continuous operation eliminates idle time between processing steps, enabling sustained high-rate production while managing system complexity through standardized modular components.
Solution Approach 2:
The continuous production system is segmented into distinct functional modules (vacuum extraction chambers, sealing chambers, conveying mechanisms, quality control stations) that can be independently designed, manufactured, and maintained. This modular segmentation allows the complex continuous production system to be built from manageable units, facilitating easier operation and maintenance while achieving high productivity through coordinated operation of all segments.
3Reliability
If high-temperature sealing is used to seal the vacuum glass, then the sealing effect is good, but annealing issues occur
Solution Approach 1:
The sealing process parameters are changed by replacing high-temperature sealing with low-temperature or room-temperature sealing methods. This parameter change maintains adequate sealing effect while avoiding the harmful annealing issues caused by high-temperature exposure to tempered glass, thus resolving the contradiction between sealing reliability and avoidance of thermal damage.
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
Enables continuous processing of vacuum glass members with high vacuum degrees, improving production efficiency and reducing costs by maintaining a consistent high vacuum environment and avoiding annealing issues associated with high-temperature sealing.
Implementation Method 1
each vacuum chamber is provided with a vacuum obtaining system and a vacuum detection device
Implementation Method 2
the sealing object 14d can be formed by mutually and directly welding metal layers preset on the upper and lower glass plates, can be made of low melting-point glass powder, can also be formed by welding a metal sealing sheet with U-shaped section and the metal layers preset on the upper and lower glass plates
Data Source
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AI summary
The present invention discloses a device for continuously processing vacuum glass member. The device comprises a loading table, front-end auxiliary vacuum chambers, a main vacuum chamber, a back-end auxiliary vacuum chambers and a unloading table sequentially along the advancing direction of the glass; the device also comprises a glass plate conveying mechanism and an electric control system; the glass plate conveying mechanism is used for conveying glass plates in the processing device; the vacuum chambers are independent from one another and are provided with a vacuum obtaining system and a vacuum detection device respectively, the vacuum degrees of the front-end auxiliary vacuum chambers and the back-end auxiliary vacuum chambers are equal to or lower than the vacuum degree of the main vacuum chamber, and the two auxiliary vacuum chambers provide a transition vacuum space at the front and rear ends of the main vacuum chamber respectively; a plate combining device and a sealing device are arranged in the main vacuum chamber, the two devices can perform plate combining and sealing operations on the glass plates in the main vacuum chamber; and the electric control system is used for performing the system control for a vacuum sealing process and an equipment operation flow.