Vacuum Insulated Panel Edge Seal With Laser-Activated Ti-Al-V Getter
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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, and 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 with a multi-layer edge seal structure comprising a main seal layer and primer layers, where the main seal layer is made of a Ti-Al-V crystalline phase getter material activated by laser treatment, and a localized laser firing process is used to form the seal, reducing thermal stress and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sealing processes are used to form the edge seal, then the glass substrates undergo significant de-tempering, but the seal formation is achieved
Solution Approach 1:
The patent applies localized laser firing to selectively heat and seal the edge seal structure, changing the thermal parameters from conventional broad heating to focused localized heating. This allows the seal to be formed while minimizing thermal stress on the glass substrates, preserving their temper strength and reducing de-tempering effects
Solution Approach 2:
The patent replaces conventional mechanical or broad thermal sealing processes with laser-based sealing. The laser provides precise energy delivery that activates the getter material and forms the seal without the excessive thermal stress associated with traditional sealing methods, thereby maintaining glass substrate strength
2Reliability
If conventional getter materials are used, then manufacturing is simpler, but sorption performance in vacuum is insufficient
Solution Approach 1:
The patent changes the physical and chemical parameters of the getter material by forming a Ti-Al-V crystalline phase through laser treatment. This phase transformation enhances the sorption performance of the getter material in the vacuum environment, allowing it to more effectively trap residual gases and maintain vacuum integrity
Solution Approach 2:
The patent uses a composite getter material comprising Ti, Al, and V elements in specific proportions that form a Ti-Al-V crystalline phase. This composite material provides superior sorption performance compared to conventional single-element getters, while the laser activation process integrates seamlessly into the manufacturing workflow
3Reliability
If high thermal energy is applied to form the seal, then sealing is achieved, but transient thermal stress increases
Solution Approach 1:
The patent applies thermal energy locally to the edge seal structure rather than uniformly across the entire panel. The localized laser firing concentrates heat only where needed to activate the getter and form the seal, minimizing the overall thermal stress on the glass substrates and reducing transient thermal stress
Solution Approach 2:
The laser firing process applies thermal energy in a controlled, periodic manner to progressively seal the edge seal structure. This controlled heating approach allows stress to be managed and dissipated, reducing peak transient thermal stress while still achieving complete seal hermeticity
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 vacuum hermeticity, preserves compressive and tensile stresses in the glass substrates, reduces transient thermal stress, and improves manufacturing efficiency, resulting in a durable and cost-effective vacuum insulating panel that meets safety standards.
Implementation Method 1
a localized laser firing process is used to form the seal
Implementation Method 2
heating and melting the main seal layer and primer layers
Implementation Method 3
a getter comprising getter material, wherein the getter material comprises a Ti-Al-V crystalline phase
Data Source
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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 laser activated in a manner which causes the getter to transform and realize a Ti-Al-V phase (e.g., Al3V0.333Ti0.667) of crystallite material. The getter may be a thin film getter and/or may be elongated in shape.