Laser-Processed Vacuum Panel Edge Seals for Low Thermal Stress
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 poor durability due to thermal stress and edge seal failures.
Innovation Solution
A method for making vacuum insulating panels using laser heating to transform TeO4 into TeO3 in the seal material, resulting in a more durable and hermetic edge seal, while also reducing thermal stress and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermal processing is used to fire seal material, then the seal material is sintered to form a seal, but significant de-tempering of glass substrates occurs and thermal stress increases
Solution Approach 1:
The patent replaces conventional thermal field processing with laser beam processing. The laser beam provides localized, controlled heating that fires the seal material without subjecting the entire glass substrate to high temperatures, thereby maintaining glass compressive stress while achieving reliable seal hermeticity.
Solution Approach 2:
The laser beam applies heat locally to the seal material at the edge of the glass substrate rather than heating the entire substrate. This localized processing allows the seal material to be sintered while the bulk of the glass substrate remains at lower temperatures, preserving its tempering and reducing thermal stress.
2Reliability
If conventional thermal processing is used to fire seal material, then the seal is formed, but manufacturing costs increase due to energy consumption and process time
Solution Approach 1:
The patent replaces energy-intensive conventional thermal processing with laser beam processing. The laser provides concentrated energy delivery that reduces overall energy consumption and shortens processing time, thereby lowering manufacturing costs while producing durable seals.
Solution Approach 2:
The laser beam can be applied in a controlled, periodic manner to the seal material, allowing for efficient energy delivery and rapid processing. This periodic action enables quick heating and cooling cycles that reduce total process time and energy consumption compared to conventional continuous thermal processing.
3Reliability
If conventional thermal processing is used to fire seal material, then the seal is formed, but edge seal failures occur due to thermal stress
Solution Approach 1:
The laser beam heats only the seal material at the edge of the substrate, creating a localized temperature gradient. This local heating approach minimizes thermal stress in the bulk glass substrate while still achieving complete sintering of the seal material, preventing edge seal failures.
Solution Approach 2:
The patent replaces conventional thermal processing with laser processing, which provides superior temperature control and localization. This substitution reduces overall thermal stress in the system while maintaining effective seal formation, thereby preventing thermal stress-induced seal failures.
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 improves the thermal insulation efficiency, maintains the compressive stress of tempered glass, reduces de-tempering, and enhances the durability and hermeticity 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
Implementation Method 3
evacuating the gap to a pressure less than atmospheric pressure
Data Source
Figure 1
Figure 2
Figure 3
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.%.