Vacuum Insulated Panel Edge Seal Using Laser Hermetic Sealing
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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, lack of durability, and hermeticity problems due to edge seal damage, slow processing times, and high thermal de-tempering rates, which hinder their commercial viability and compliance with safety codes.
Innovation Solution
A vacuum insulating panel with a hermetic edge seal comprising a main seal layer and primer layers, utilizing a laser heating process to minimize transient thermal stress and maintain compressive and tensile stresses in the glass substrates, ensuring compliance with safety standards and improving durability and hermeticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heating processes are used to seal the edge seal, then the seal hermeticity is improved, but the glass substrates undergo significant de-tempering and high thermal stress
Solution Approach 1:
The patent replaces conventional mechanical/conventional heating sealing systems with a laser-based sealing system. The laser heating apparatus provides localized, controlled thermal energy to the edge seal region, achieving hermetic sealing while minimizing heat diffusion to the glass substrates, thus reducing thermal de-tempering and stress
Solution Approach 2:
The laser heating process applies thermal energy locally to the edge seal region rather than uniformly heating the entire glass panel. This localized heating approach seals the edge effectively while maintaining the tempering quality and stress state of the bulk glass substrates
2Reliability
If conventional sealing methods are used, then the seal hermeticity is improved, but the manufacturing cost increases and processing time slows
Solution Approach 1:
The laser heating apparatus replaces slow, energy-intensive conventional heating methods with a rapid, focused laser beam process. This enables faster sealing cycles while maintaining hermeticity, directly improving manufacturing productivity and reducing processing time
Solution Approach 2:
The laser heating process can be applied in controlled pulses or continuous modes with optimized parameters, enabling rapid heating and cooling cycles that achieve sealing quickly without prolonged exposure, thereby increasing processing speed
3Productivity
If laser heating process is used to minimize thermal stress, then the manufacturing cost is reduced and processing speed is improved, but the seal hermeticity may be compromised
Solution Approach 1:
The laser heating process uses optimized parameters (power density, scanning speed, focal position, pulse duration) to achieve the minimum effective heating required for sealing. This ensures hermeticity is achieved with minimal thermal input, maintaining both productivity and reliability
Solution Approach 2:
The laser heating system incorporates process control and monitoring to ensure consistent sealing quality. By monitoring and controlling laser parameters and heating patterns, the system maintains hermeticity while operating at high speed with minimal thermal stress
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, enhances durability and hermeticity, and reduces manufacturing costs by using a laser heating process that minimizes de-tempering and edge seal flaws, enabling cost-effective production.
Implementation Method 1
utilizing a laser heating process to minimize transient thermal stress and maintain compressive and tensile stresses in the glass substrates
Implementation Method 2
The gap between the substrates may be at a pressure less than atmospheric pressure to provide insulating properties. Providing a vacuum in the space between the substrates reduces conduction and convection heat transport
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 vacuum insulating panel may include a multi-layer edge seal structure, including at least one layer including boron oxide (e.g., B2O3 or any other stoichiometry).