Laser-Processed Vacuum Panel Seals for Hermetic Edge Firing
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Solution Overview
Problem
Conventional vacuum insulated glass perimeter sealing systems face issues such as significant de-tempering of glass substrates, high de-tempering rates, lack of durability, hermiticity problems, slow processing times, and increased need for heat soak testing, which hinder their commercial use.
Innovation Solution
The use of laser heating to transform TeO4 into TeO3 and V2O5 into VO2 in the seal material, resulting in a more efficient edge seal formation with improved hermiticity, durability, and reduced de-tempering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heating methods are used to fire seal material, then seal formation is achieved, but significant de-tempering of glass substrates occurs
Solution Approach 1:
The patent applies selective laser heating to locally fire only the seal material at the perimeter of the glass substrates, while the bulk glass substrates remain relatively cool. This localized heating approach allows the seal to be fired without subjecting the entire glass assembly to high temperatures that would cause de-tempering.
Solution Approach 2:
The patent replaces conventional thermal field heating (oven or furnace heating) with a focused laser beam heating system. This substitution enables precise control of the heating zone and duration, allowing seal material to be fired while minimizing heat transfer to the glass substrates and preventing de-tempering.
2Reliability
If conventional heating methods are used to fire seal material, then seal formation is achieved, but processing time increases
Solution Approach 1:
The patent employs periodic or pulsed laser heating to fire the seal material. The laser can be applied in controlled pulses or passes, heating the seal material incrementally to its firing temperature without requiring prolonged exposure. This periodic action achieves complete seal formation faster than conventional continuous heating methods.
Solution Approach 2:
By replacing conventional slow thermal field heating with focused laser heating, the patent dramatically reduces processing time. The laser delivers concentrated energy directly to the seal material, achieving rapid heating and firing rates that cannot be matched by bulk heating methods, thus improving manufacturing productivity.
3Reliability
If conventional heating methods are used to fire seal material, then seal formation is achieved, but thermal stress in glass substrates increases
Solution Approach 1:
The selective laser heating confines thermal energy to the seal material region, creating a localized temperature gradient rather than a uniform temperature increase across the glass substrates. This localized approach minimizes differential thermal expansion and reduces induced transient thermal stress in the glass.
Solution Approach 2:
The rapid laser heating process quickly brings the seal material to firing temperature and completes the firing cycle before significant heat can conduct into the glass substrates. This rapid processing 'skips' the prolonged thermal exposure that would otherwise create large thermal gradients and high stress in the glass.
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 proposed solution enhances the sealing efficiency, maintains the thermal tempering of glass substrates, reduces induced transient thermal stress, and improves the overall durability and hermiticity of the vacuum insulating panels.
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
causes TeO4>TeO3 in the first seal material to transform into TeO3>TeO4 due to said laser heating
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. %.