Vacuum Glass Stack Assembly to Prevent Spacer Collapse
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Solution Overview
Problem
Existing glass panel units face challenges in achieving both improved thermal insulation and mechanical strength, particularly due to the collapse of spacers under pressure during assembly, which compromises the integrity of the evacuated space and overall performance.
Innovation Solution
A method involving the assembly of a glass panel unit and a transparent plate via an intermediate film within an evacuated chamber, where the assembly is heated to soften the film and cured under vacuum, ensuring the spacers are not compressed beyond their compressive strength, thereby maintaining the evacuated space and enhancing mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the glass panel unit is assembled with a transparent plate via an intermediate film under atmospheric pressure, then the assembly process is simple, but the spacers collapse under pressure causing loss of evacuated space integrity
Solution Approach 1:
The patent applies vacuum environment (inert atmosphere without air pressure) during the assembly process to eliminate atmospheric pressure that would otherwise collapse the spacers. The glass panel unit and transparent plate are assembled inside an evacuated chamber, maintaining vacuum conditions throughout the bonding process to preserve the evacuated space integrity while achieving reliable attachment.
2Strength
If the intermediate film is heated to soften it for bonding, then the bonding strength is improved, but the spacers may collapse under the combined pressure and heat
Solution Approach 1:
The heating and bonding process is conducted inside an evacuated chamber that maintains vacuum conditions. This eliminates atmospheric pressure during heating, allowing the intermediate film to be softened and bonded without the spacers collapsing under pressure. The vacuum environment permits thermal processing while protecting the delicate spacer structure.
3Device complexity
If the assembly is performed in atmospheric conditions, then the process equipment is simple, but the mechanical strength of the final product is reduced due to spacer collapse
Solution Approach 1:
The patent uses an evacuated chamber to maintain vacuum conditions during assembly, preventing spacer collapse and ensuring high mechanical strength of the final product. While this adds equipment complexity compared to atmospheric assembly, it is necessary to achieve the required structural integrity and prevent evacuation failure.
Solution Approach 2:
The evacuation of the chamber is performed before assembly begins, creating the protective vacuum environment in advance. This preliminary action ensures that the spacers are protected from collapse before any bonding or pressing operations occur, maintaining structural integrity throughout the subsequent manufacturing steps.
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 results in a multi-layer stack with superior thermal insulation and mechanical strength by preventing spacer collapse and maintaining the evacuated space, thus improving the structural integrity and performance of the glass panel unit.
Implementation Method 1
heating a multi-layer assembly, including the glass panel unit, the intermediate film, and the transparent plate attached via the intermediate film to the glass panel unit, inside an evacuated chamber to soften the intermediate film
Implementation Method 2
keeping the inside of the chamber evacuated until the intermediate film is cooled and cured
Implementation Method 3
assembling the glass panel unit and the transparent plate together via the intermediate film inside an evacuated chamber
Data Source
AI summary
An object of the present disclosure is to provide a method for manufacturing a multi-layer stack with excellent mechanical strength and thermal insulation properties. A multi-layer stack includes a glass panel unit, an intermediate film, and a transparent plate attached via the intermediate film to the glass panel unit. The glass panel unit includes a first glass panel, a second glass panel, and an evacuated space interposed between the first glass panel and the second glass panel. The method includes assembling the glass panel unit and the transparent plate together via the intermediate film inside an evacuated chamber.