Multi-Row Vacuum Panel Seal for Thermal Stress Durability
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Solution Overview
Problem
Conventional vacuum insulated glass perimeter sealing systems face issues such as significant de-tempering of glass substrates, high de-tempering rates, lack of durability due to thermal stress, and thermal bridge problems, which hinder their commercial use and compliance with safety codes.
Innovation Solution
The implementation of a vacuum insulating panel with a hermetic edge seal comprising multiple seal layers, including a main seal layer and primer layers, which are designed to reduce thermal stress and improve durability by using a laser sintering process with optimized layer thicknesses and materials, such as tellurium oxide-based ceramic materials, to create a more efficient and durable seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional single-layer hermetic edge seal is used, then the manufacturing process is simpler, but the glass substrates suffer from significant de-tempering and thermal stress, reducing durability
Solution Approach 1:
The hermetic edge seal is divided into multiple discrete layers (first seal layer, second seal layer, third seal layer) with different materials and functions. The first seal layer provides hermetic sealing, the second seal layer provides mechanical strength, and the third seal layer provides thermal stress relief, allowing each layer to be optimized independently for its specific function while collectively solving the durability problem.
Solution Approach 2:
The patent employs a composite multi-layer seal structure combining different materials (e.g., ceramic materials in the first seal layer, glass frit in the second seal layer, and flexible materials in the third seal layer) to achieve properties that cannot be obtained with a single material, specifically balancing hermeticity, mechanical strength, and thermal stress resistance.
2Reliability
If a thicker single-layer seal is used to improve hermeticity, then the seal width increases, but the thermal stress and risk of micro-cracking increase
Solution Approach 1:
The seal is segmented into multiple thin layers instead of one thick layer. Each layer is approximately 0.5-2 mm thick, which is sufficient for its specific function but thin enough to minimize thermal stress and micro-cracking risk. The cumulative effect of multiple layers achieves the required hermeticity without the harmful effects of a single thick layer.
Solution Approach 2:
Different regions of the seal have different thicknesses and material properties optimized for their specific functions. The first seal layer is thicker for hermeticity, the second seal layer is optimized for mechanical strength, and the third seal layer is designed for thermal stress relief, allowing each local region to have the quality needed for its specific purpose.
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 solution enhances the mechanical strength and durability of the vacuum insulating panels, allowing them to pass thermal stress testing and meet safety fragmentation requirements, while reducing the risk of micro-cracking and de-tempering, thus improving the overall performance and safety of the panels.
Implementation Method 1
which are designed to reduce thermal stress and improve durability by using a laser sintering process
Implementation Method 2
by using a laser sintering process with optimized layer thicknesses and materials
Implementation Method 3
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
Implementation Method 4
provides insulating properties. For example, a vacuum insulating panel provides thermal insulation resistance by reducing convective energy between the two substrates, reducing conductive energy
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-row edge seal structure.