Vacuum Insulated Panel Tube Seal Using Laser Wicking
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Solution Overview
Problem
Conventional vacuum insulating panels face issues with seal structures for evacuation tubes, leading to breakage and cracking, which compromises hermeticity and results in premature window failures.
Innovation Solution
The use of a laser beam to heat the tube seal material, causing it to wick upwardly and form a desirable shape, creating a hermetic seal with a capillary effect, and ensuring sufficient bonding coverage between the seal structure and the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional seal structures for evacuation tubes are used, then the manufacturing process is simple, but the seal structure breaks and cracks leading to loss of hermeticity
Solution Approach 1:
The patent changes the geometric parameters of the seal structure by introducing an inclined outer peripheral sidewall with specific angle ranges (α: 30-75 degrees with the tube axis, ε: 60-150 degrees with the support surface). This parameter optimization prevents stress concentration and cracking while maintaining hermeticity, resolving the contradiction between reliability and structural simplicity.
Solution Approach 2:
The patent applies preliminary action by pre-forming the inclined sidewall geometry in the seal structure before evacuation and sealing operations. This pre-configured geometry prevents future crack formation and maintains hermeticity throughout the product lifecycle, addressing the reliability issue before it manifests.
2Ease of manufacture
If the seal structure is simplified, then manufacturing is easier, but breakage and cracking occur compromising hermeticity
Solution Approach 1:
The patent optimizes geometric parameters (angles α and ε) to create a seal structure that is both easy to manufacture and highly reliable. The specific angle ranges allow for straightforward molding and assembly while preventing stress concentration that leads to cracking, thus resolving the contradiction between ease of manufacture and seal integrity.
3Reliability
If laser heating is used to form the seal, then adhesion and hermeticity improve, but manufacturing complexity increases
Solution Approach 1:
The patent replaces conventional mechanical sealing methods with laser heating technology. The laser beam (e.g., CO2 laser) locally melts and fuses the seal material to the substrates, creating superior adhesion and hermeticity. This substitution resolves the contradiction by providing enhanced reliability through a more advanced manufacturing approach.
Solution Approach 2:
The patent utilizes phase transitions of the seal material during laser heating, where the material melts and then solidifies to form a strong bond. This phase change mechanism enables superior adhesion and hermeticity, resolving the contradiction between improved reliability and increased process complexity.
4Productivity
If conventional evacuation tube seals are used, then manufacturing is faster, but premature window failures occur
Solution Approach 1:
The patent replaces conventional mechanical sealing with laser-based sealing, which actually accelerates the manufacturing process while eliminating premature failures. The laser sealing method is faster and more reliable than traditional methods, thus resolving the contradiction between productivity and durability.
Solution Approach 2:
The patent optimizes geometric parameters of the seal structure (inclined sidewalls with specific angles) to prevent crack formation and premature failures. These parameter changes maintain manufacturing efficiency while dramatically improving window durability, resolving the contradiction between productivity and reliability.
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
This method improves evacuation tube seal adhesion, enhances hermeticity, reduces seal and glass breakage, minimizes crack formation, increases moisture resistance, and enhances thermal stability and durability, while also allowing for faster manufacturing.
Implementation Method 1
A laser beam (e.g., substantially donut-shaped and/or ring-shaped laser beam, or a spot laser beam of sufficient spot size that can be manipulated/moved around seal material) may be used to heat the tube seal material
Implementation Method 2
causes the tube seal material to wick upwardly along the tube and form a desirable shape and hermetic seal, such as via a capillary effect
Data Source
AI summary
A vacuum insulating panel may include: a first substrate; a second substrate; a plurality of spacers provided in a gap between at least the first and second substrates, wherein the gap is at pressure less than atmospheric pressure; an evacuation tube extending at least partly into an aperture in one of the substrates; and an evacuation tube seal at least partially surrounding the tube. A laser beam (e.g., spot laser beam, or donut/ring-shaped laser beam) may be used to heat the tube seal material in a manner which causes the tube seal material to wick upwardly along the tube and form a desirable shape and hermetic seal around the tube.