Vacuum Insulated Panel Sealing for Hermetic Low-Stress Glass
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Solution Overview
Problem
Conventional vacuum insulated glass panels face issues such as significant de-tempering of glass substrates, high manufacturing costs, durability problems due to thermal stress, and hermeticity issues, which hinder their commercial viability and compliance with safety codes.
Innovation Solution
A vacuum insulating panel design using a multi-layer edge seal structure with a main seal layer and primer layers, combined with laser heating to minimize transient thermal stress and ensure hermeticity, while maintaining compressive and tensile stresses within the glass substrates, and employing a getter to maintain vacuum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional vacuum insulated glass panels are manufactured, then thermal insulation is provided, but significant de-tempering of glass substrates occurs and manufacturing costs are high
Solution Approach 1:
The edge seal is divided into multiple layers: a first seal layer, a second seal layer, and optionally a third seal layer. This segmentation allows each layer to perform specific functions - the first layer provides initial sealing, the second layer enhances hermeticity, and the third layer (when present) provides additional protection. This layered approach maintains glass substrate stress while enabling cost-effective manufacturing through optimized material usage and processing.
Solution Approach 2:
The patent modifies the sealing parameters by controlling the thickness and material composition of each seal layer. The first seal layer has specific thickness parameters, and the second seal layer has different thickness parameters optimized for its function. These parameter changes enable the seal to maintain hermeticity while minimizing thermal stress on the glass substrates, thereby maintaining compressive and tensile stresses within safe limits.
2Reliability
If conventional sealing methods are used, then vacuum is provided, but hermeticity issues occur
Solution Approach 1:
The seal structure is segmented into multiple functional layers, where each layer contributes to the overall hermeticity. The first seal layer provides the primary seal, the second seal layer reinforces the hermetic barrier, and the third seal layer (when included) adds an extra level of protection. This segmentation achieves superior hermeticity without requiring overly complex single-layer solutions.
Solution Approach 2:
The patent employs composite seal structures combining different materials with complementary properties. The first seal layer and second seal layer are made of materials selected for their specific advantages - such as flexibility, adhesion, or barrier properties. This composite approach ensures hermeticity while keeping the overall structure manageable in complexity.
3Duration of action of stationary object
If thermal stress is reduced, then durability is improved, but manufacturing processing efficiency may be affected
Solution Approach 1:
The multi-layer seal structure allows for staged processing where each layer can be applied and cured independently. This segmentation enables optimized processing parameters for each layer, reducing overall manufacturing time while ensuring each layer contributes to stress reduction and durability enhancement.
Solution Approach 2:
The patent applies preliminary sealing actions with the first seal layer before adding the second seal layer. This preliminary action allows the first layer to set and provide a stable base, reducing the complexity of subsequent processing steps and improving overall manufacturing efficiency while maintaining durability.
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 solution maintains high compressive and tensile stresses in the glass substrates, ensures structural integrity under thermal differentials, and reduces manufacturing costs by improving processing efficiency and durability, thereby meeting safety standards and reducing breakage rates.
Implementation Method 1
a getter, wherein the getter as viewed from above may be elongated in shape
Implementation Method 2
combined with laser heating to minimize transient thermal stress and ensure hermeticity
Implementation Method 3
Providing a vacuum in the space between the substrates reduces conduction and convection heat transport, and thus provides insulating properties
Data Source
AI summary
A vacuum insulating panel includes first and second substrates (e.g., glass substrates), a hermetic edge seal, a pump-out port, and spacers sandwiched between at least the two substrates. The gap between the substrates may be at a pressure less than atmospheric pressure to provide insulating properties. The panel may include a getter. The getter may be a thin film getter and/or may be elongated in shape.